Assembly (page 3 of 3)

25. Locate tang of retaining wire in hole and using tool 18G 1637/2, rotate lock stop clockwise and wind wire into place until hole just shows in slot.
26. Seal slot with RTV sealant.
27. Push rack fully to support bush end.
28. Fit rack limiter and using 18G 1637/2, tighten to 80 Nm.
29. Extend rack from pinion end and hold flat of rack teeth in soft jawed vice. Do not overtighten.
30. Fit tie – rods to rack and tighten by hand.

Note: If tie – rods are to be reused, fit to opposite end of rack from original position.

31. Fit tool 18G 1440/2 to inner ball joints and with torque wrench in line with handle, tighten to 55 Nm (actual fitted torque 80 Nm).
32. Stake each ball joint flange into rack slot.
33. Hold pinion housing bracket in soft jawed vice with yoke housing upwards.
34. Centralise rack (equal each side).
35. Ensuring yoke housing threads are kept free of grease, fit yoke and spring.
36. Screw yoke cover one turn into housing and apply Loctite 542 around threads.

CAUTION: Adjust yoke cover damper immediately after applying Loctite before curing commences.

37. Ensure rack is centralised and screw yoke cover into place, tighten to 4 Nm using 18G 1637/1.
38. Using a felt tipped pen, mark a line on yoke cover and housing. Mark a second line on housing 10 mm (30°) anti – clockwise. Turn cover anti – clockwise to align with second mark.
39. Pull rack through its full travel side to side. Rack should operate freely over full travel without binding.
40. If binding is felt, carefully turn yoke cover a further 3 mm (10°) and recheck full travel. If still tight, repeat above.

CAUTION: Total backing off after tightening must not exceed 16 mm (50°). If rack binds after maximum adjustment, renew assembly.

41. Stake housing threads above yoke cover at 3 new positions.

CAUTION: Ensure staking does not contact yoke cover.

42. Smear grease to bellows location on tie – rods.
    Apply any remaining grease to rack teeth.
43. Centralise rack.
44. Push bellows onto tie – rods and secure to rack housing with large clips.
    Secure bellows to tie – rods with small clips.
    Check that bellows can rotate on tie – rods.
45. Screw locknuts equally onto tie – rods to dimension noted on removal or 25 mm. Screw ball joints up to locknuts and lightly tighten locknuts.