240 L4-2127cc 2.1L SOHC B21F (1982)
c. Preload is adjusted by altering the bearing washer under the cover. Washers are available in various sizes.
6.
Remove pinion assembly, bearings and spacers.
7.
Install all rings on valve body grooves.
8.
Install seal and spacer ring in pinion housing.
9.
Install bronze bushing in spacer tube, chamfered side down.
10.
Install spacer tube seal in spacer tube.
11.
Install O-ring and washer on spacer tube.
12.
Install seal, bearings and star washer in right side housing.
13.
Fill lock ring grooves and coat surrounding area with suitable grease, then slide spacer tube into steering rack from smooth end and pass it quickly
over lock ring grooves.
14.
Install piston, thrust washers and lock ring on rack.
15.
Install center tube locking collars and lock rings. Also apply a suitable lubricant on collar threads and lock rings.
16.
Place right side housing in a vise and using tool No. 5178 attached to a torque wrench, install center tube on right side housing. Torque retaining
collar to 88 ft. lbs. Ensure scribe marks made previously are aligned.
17.
Install rack and spacer tube as a unit in pinion housing.
18.
Using tool No. 5178 attached to a torque wrench, install center tube to pinion housing. Torque retaining collar to 88 ft. lbs. Ensure scribe marks
made previously are aligned.
19.
Punch a mark in aluminum housing at one of the recesses on each housing to lock retaining collars.
20.
Install pre-tensioning piston, without O-ring, in housing.
21.
Set up pre-tension measuring fixture No. 5865 using one cover bolt hole fitted with a 45mm 8mm bolt. Assemble tool with pre-tension spring
between bolt head and tool.
22.
Move gear from lock to lock and ensure it does not bind or jam.
23.
Using a suitable micrometer, measure distance between housing face and piston top, checking measurement at three different points of steering
rack. Subtract .004-.006 inch from smallest reading obtained and select a washer of the approximate thickness. Washers are available in thickness
of .083-.114 inch in increments of .0019 inch.
24.
Remove tool No. 5865 and install O-ring and spring for pre-tension piston. Install selected washer and cover. Torque cover bolts to 15 ft. lbs.
25.
Reverse procedures 1 through 5 of disassembly procedure for remainder of assembly and note the following:
a. Torque pressure pipe fittings to 15 ft. lbs.
b. Fill rubber bellows with 3-4 ounces of suitable lubricant.
