With Power Steering

Fig. 17 Disassembled view of power steering gear. 1986-88 RX-7:

Gear Disassembly

1. Secure gear and linkage assembly in a suitable vise.
2. Mark position of tie rod ends for assembly reference, then remove tie rod ends from tie rods, Fig. 17
3. Cut boot wires, then remove boot clamps and the boots.
4. Secure rack gear in vise, then remove tie rods and spring pins.
5. Rotate rack stopper clockwise until end of clip projects out, then turn in opposite direction to remove clip, rack stopper and rack bushing.
6. Remove rack bushing oil seal using a suitable screwdriver. When removing oil seal, use care to avoid damaging rack bushing.
7. Remove locknut and yoke plug, then the spring and racket support.
8. Remove pinion plug and locknut from housing.
9. Remove dust cover and snap ring from housing.
10. Carefully tap control valve assembly out of housing using a suitable punch.
11. Carefully remove O-ring and piston ring from control valve assembly.
12. Remove bearing from control valve using a suitable press.
13. Remove plunger and bearing from housing.
14. Remove washer and oil seal from rack.
15. Remove oil pipes from rack housing.
16. Position oil seal remover (tool No. 49 F032 311) on end of rack, then remove the rack assembly.

Gear Assembly

1. Before assembly, the following components should be coated or packed with lithium base grease or equivalent:
a. Pinion gear and rack teeth.
b. Tie rod ball joints.
c. Inside of both boots.
d. Friction and rear surfaces of rack support.
e. Pinion installation position in gear housing. Suitable transmission fluid should also be applied to all seals, O-rings and bearings during assembly.
2. Secure rack housing in a suitable vise.
3. Install O-ring and piston ring into piston ring groove in rack.
4. Carefully slide rack into housing, using vinyl protective cover over rack gear.
5. Connect oil pipes to rack housing.
6. Install washer and rack housing oil seal using tools 49 F032 303 and 49 F032 304 or equivalents.
7. Press bearing and oil seal into rack housing.
8. Install plunger into housing.
9. Slide control valve assembly into tool No. 49 F032 309 to compress the rings, then slide assembly into housing.
10. Install control valve snap ring, then the dust cover and oil seal.
11. Install pinion locknut and torque to 14-22 ft.lbs.
12. Apply suitable sealant to pinion plug threads, then install plug and torque to 36-51 ft.lbs. Stake pinion plug in place after tightening.
13. Install rack support and spring.
14. Apply suitable sealant to yoke plug threads. Torque yoke plug to 14-22 ft.lbs. then back off 25-35°.
15. Install yoke plug locknut and torque to 29-43 ft.lbs.
16. Install rack bushing oil seal and O-ring. Press seal in until surface of seal is even with rack bushing.
17. Position suitable protector over rack and install bushing into rack housing.
18. Position rack stopper in housing and turn until hole in stopper aligns with hole in housing.
19. Position retaining clip on rack stopper, then rotate stopper to seat clip.
20. Secure rack gear in vise, then install tie rods and torque to 51-72 ft.lbs. Install new spring pins.
21. Measure pinion preload using adapter tool No. 49 0180 510B or equivalent and a suitable spring scale. Preload should measure 24.7-45.9 ounces.
22. Install boots, wrapping a new wire around boot twice and twisting off four times.
23. Install boots clamps and ensure boots are not twisted or otherwise deformed.
24. Install tie rod ends, referring to alignment marks made during disassembly.