780 V6-2849cc 2.8L SOHC B280F (1987)
e. Install plastic spacer with bevelled side facing inward, then remove tape.
13.
Position lock sleeve with cut-out sections facing end of rack assembly. Lock wire opening should be aligned with elongated hole in tube assembly.
14.
Install lock wire by connecting on to lock sleeve. Turn sleeve until wire is correctly positioned in groove.
15.
Center rack in housing. Pack teeth with grease, then place into housing with flat side facing either the 2, 3, or 4 o'clock position. Place rack into
housing so that rack end protrudes 2.2 inches on late models, or 2.4 inches on early models with pinion in position. Ensure pinion and rack mesh
and flat side of pinion is in either 2, 3, or 4 o'clock position.
16.
Apply adhesive tape to pinion splines, then lubricate tape.
17.
Install the following:
a. Install bearing onto pinion. Turn bevelled side down, then tap bearing into position. Use drift 5048 or equivalent and a plastic hammer to
tap bearing into position. Modify drift by drilling inner section to a diameter of .87 inch and grinding down drift end to 1.34 inch.
b. Coat seal with suitable grease, then install with seal lip facing downward. Tap seal into position using drift 5048 or equivalent and a plastic
mallet.
c. Install lock ring.
d. Apply suitable lubricant onto dust cover, then install cover.
18.
Install pinion lock nut and torque nut to 27 ft. lbs.
19.
Pack plug seal with grease, then install plug.
20.
Place pre-tension piston into housing and measure clearance between housing and piston. Use a feeler gauge and steel ruler for measurements.
Press piston toward rack assembly, then slide rack back and forth and note maximum clearance. Thickness of adjusting shim to be used must equal
measured clearance obtained between pre-tension piston and housing. If necessary, add one extra adjusting shim (.002-.006 inch) to obtain correct
end play.
21.
Install spring, adjusting shims and gasket. Install cover. Torque cover attaching bolts to 12 ft. lbs.
22.
Check pinion torque as follows:
a. Install torque gauge 9177 or equivalent, on to pinion shaft using adapter 5179 or equivalent. Move rack assembly back and forth between end
positions.
b. Correct torque value obtained should be 5-15 inch lbs.
c. If torque is too high at any position of rack, stop rack in that position and readjust pre-tension. If rack binds with the pre-tension piston
removed, rack assembly may be warped and should be replaced.
d. Remove torque gauge and adapter.
23.
Install steering rods. During installation of steering rods, rack must be prevented from rotating or pinion will be damaged.
24.
Install and lock steering rods onto rack assembly.
25.
Install bellows. Fill each bellow with approximately .7 ounces of suitable lubricant. Position bellows and secure with clamps.
26.
Install rack assembly into vehicle.
