Rack Piston and Worm Shaft Replacement - (700 Gear)

Disassembly Procedure

Tools Required
- J 21552 Rack Piston Arbor





1. Remove the pitman shaft and side cover. Refer to Steering Gear Pitman Shaft and Housing Cover Replacement - Off Vehicle (700 Gear).Pitman Shaft and Housing Cover Replacement (700 Gear)
2. Remove the housing end plug (1). Refer to Steering Gear Housing End Plug Replacement -Off Vehicle.Steering Gear Housing End Plug Replacement
3. Turn the stub shaft counterclockwise until the rack piston (2) begins to come out of the steering gear housing.
4. Remove the rack piston plug (1).
5. Insert J 21552 into the bore of the rack piston (2).
6. Hold J 21552 tightly against the worm shaft while turning the stub shaft counterclockwise. Turning the stub shaft forces the race piston (2) onto J 21552. The rack piston balls remain In place.





7. Remove the following items as an assembly from the steering gear housing (9): The rack piston (4) The rack piston balls (5) J 21552
8. Remove the valve. Refer to Steering Gear Valve Replacement- Off Vehicle.Steering Gear Valve Replacement
9. Remove the worm shaft (14).
10. Remove the thrust bearing (12) and the flat races (1 1) (13).
11. Remove the flat races (11).
12. Remove J21552from the rack piston (4).
13. Remove the rack piston balls (5).
14. Remove the following items from the rack piston (4):
14.1. The screws (8)
14.2. The clamp (7)
14.3. The ball guide (6)
15. Remove the teflon ring (2).
16. Remove the O-ring seal (3).
17. Clean all of the disassembled parts.
18. Inspect all of the disassembled parts for wear.
19. Replace the parts if necessary.

Assembly Procedure

Tools Required
- J 8947 Rack Piston Teflon Ring Compressor
- J 21552 Rack Piston Arbor





1. Install the O-ring seal (3) and the teflon ring (2).
2. Lubricate both parts with power steering fluid.
3. Install the worm shaft (14) to the rack piston (4) outside of the steering gear housing (9).

Important: Reinstall all of the rack piston balls in the rack piston. Improper rack piston ball installation may result in personal injury.

4. Fully seat the worm shaft to the rack piston.





5. Align the worm shaft spiral groove with the rack piston ball return guide hole (1).

Important: The black rack piston balls are smaller than the silver rack piston balls. Install the black and the silver rack piston balls alternately into the rack piston and the ball guide to maintain the rack piston to the worm shaft preload.

6. Lubricate the rack piston balls with power steering fluid.
7. Insert the rack piston balls through the ball return guide hole (1) while turning worm shaft (2) counterclockwise in order to install the rack piston balls into the rack piston.





8. Install the remaining rack piston balls (3) into the ball guide (1) using grease at each end (2) to retain the rack piston balls (3).





9. Install the ball guide (5) to the rack piston (4).
10. Install the ball guide clamp (6).

Notice: Refer to Fastener Notice In Service Precautions.

11. Install the screws (7).
- Tighten the screws (7) to 58 Nm (43 inch lbs.).
12. Insert J 21552 into the bore of the rack piston while turning the worm shaft counterclockwise. The turning of the worm shaft forces the rack piston onto J 21552. The rack piston balls remain in place.





13. Install the flat races (2) (4) and the thrust bearing (3) onto the worm shaft (1).





14. Install the worm shaft (4) to the steering gear housing (3).
15. Install the valve. Refer to Steering Gear Valve Replacement- Off Vehicle.Steering Gear Valve Replacement
16. Install the rack piston (2) to the worm (4) from J 21552 using J 8947 to compress the seals.

Important: Reinstall all of the rack piston balls into the rack piston. Improper rack piston ball installation may result in personal injury.

17. Hold J 21552 tightly against the worm shaft (4).
18. Turn the stub shaft clockwise until the rack piston (2) is seated on the worm shaft (4).
19. Install the rack piston plug.
- Tighten the rack piston plug to 150 Nm (111 ft. lbs.).
20. Install the housing end plug (1). Refer to Steering Gear Housing End Plug Replacement - Off Vehicle.Steering Gear Housing End Plug Replacement
21. Install the pitman shaft and side cover. Refer to Steering Gear Pitman Shaft and Housing Cover Replacement - Off Vehicle (700 Gear).
22. To adjust the steering gear, refer to:
22.1. Worm Thrust Bearing Preload Adjustment - Off VehicleWorm Thrust Bearing Preload Adjustment (Off Vehicle)
22.2. Pitman Shaft Over-Center Preload Adjustment - Off Vehicle