Assemble

Fig. 7 Installation Of Worm Shaft Housing Bearing cap:

Fig. 8 Installation Of Worm Bearing Adjuster nut:

Fig. 9 Installation Of Sector Shaft Seal:

Fig. 10 Installation Of Worm Shaft Seal:

1. Install new worm shaft bearing cup, Fig. 7. Install new adjuster plug bearing cup, Fig. 8. Install sector shaft seal in housing until it bottoms out, Fig. 9. Tap worm shaft seal into housing until it is flush with housing, Fig. 10.
2. Place housing assembly in vise with sector cover opening up.
3. Apply steering gear lubricant to sector cover bushing, sector shaft needle bearings and worm shaft bearings. Use lubricant C3AZ-19578-A or equivalent.

Fig. 11 Installation Of Worm Shaft And Ball Nut Assembly Into Gear Housing:

Fig. 12 Installation Of Sector Cover:

4. Place worm shaft thrust bearing over splined end of worm shaft. Insert worm shaft and ball nut assembly into housing, Fig. 11. Push splined end of worm shaft through bearing cup and seal.
5. Place worm shaft thrust bearing in adjuster plug bearing cup. Install adjuster plug and locknut into housing so that nearly all end play has been removed from worm shaft.
6. Insert sector shaft adjusting screw and shim(s) into T-slot.
7. Pack steering gear with C3AZ-19578-A grease or equivalent. Rotate ball nut until it is near end of its travel. Pack housing with as much grease as possible without losing it out sector shaft opening. Rotate worm shaft to other end of its travel and pack more grease into housing. Center ball nut on worm shaft.
8. Insert sector shaft assembly into housing so that center tooth of sector gear enters center rack tooth space in ball nut. Rotate ball nut teeth slightly upward to aid in alignment of gear teeth.
9. Pack remaining grease into housing.
10. Apply bead of sealant D6AZ-19562-A or equivalent to mating surfaces of sector cover and housing.
11. Place sector cover on sector adjusting screw and turn screw counterclockwise until sector cover is flush with housing, Fig. 12.
12. Install sector cover to housing attaching bolts. Check for proper lash between sector shaft and worm shaft. After lash is set, torque bolts to 40 ft. lbs.