Disassembly and Assembly
DISASSEMBLY
W/Constant Gear Ratio Steering Gear
1. Drain lubricant from gear housing by removing filler plug.
2. Secure steering gear in a suitable vise.
Fig. 7 Disassembled view of constant gear ratio manual steering gear. 1987-88 323:
3. Remove tie rod ends, then the boot wires and boots, Fig. 7. Mark the threaded part of tie rod for assembly reference.
Fig. 4 Tie rod removal & installation:
4. Remove tie rods and washers using a suitable wrench, Fig. 4.
5. On 1984-85 626 and 1986 323, proceed as follows:
a. Remove locknut, adjusting cover, spring and pressure pad from gear housing.
b. Remove dust cover, locknut, rear cover, oil seal and upper bearing.
6. On 1986-87 626, proceed as follows:
a. Remove locknut, adjust cover, spring, pressure pad plates and pressure pad from gear housing.
b. Remove dust cover, locknut, rear cover and oil seal.
7. On 1987-88 323, proceed as follows:
a. Remove nut, adjustment bolt, adjustment cover, yoke spring, spacer and support yoke from gear housing.
b. Remove oil seal, stop ring and snap ring.
Fig. 8 Removing rack. 1984-88 626, 1986-88 323 & 1988 MX-6 manual steering gear:
8. On all models, remove pinion, then the rack in direction shown, Fig. 8. To facilitate removal of pinion, strike housing gently with a soft mallet while pulling assembly out with a pair of pliers.
9. Remove mounting brackets and rubber mountings.
10. Remove lower bearing, if necessary, then the gear housing. To remove lower bearing, heat gear housing in hot water to approximately 176°F, then tap bearing out with a wooden hammer.
Fig. 10 Disassembled view of variable gear ratio manual steering gear. 1986-88 323:
W/Variable Gear Ratio Steering Gear
1. Drain lubricant from steering gear housing, then install steering gear assembly in a suitable vise, Fig. 10.
2. Remove tie rod end. Mark threaded portion of tie rod for reference when reassembling.
3. Uncrimp tie rod lock washer, then remove tie rod from rack.
4. Remove adjust cover locknut, adjust cover, spring, pressure pad plate and pressure pad.
5. Remove pinion dust cover and locknut, then the pinion plug using a suitable tool.
6. Remove pinion plug oil seal from pinion plug using a suitable tool.
Fig. 8 Removing rack. 1984-88 626, 1986-88 323 & 1988 MX-6 manual steering gear:
7. Remove pinion bearing and pinion from gear housing, then the rack in direction shown, Fig. 8.
8. Unlock bushing from housing by pushing against each of the three lock points with a suitable screwdriver, then remove bushing from housing.
9. Remove mounting brackets and rubber mountings from gear housing.
ASSEMBLY
W/Constant Gear Ratio Steering Gear
1. Before assembly fill or coat following parts with lithium base grease.
a. Pinion bearing and teeth.
b. Inside the gear housing.
c. Oil seal lip.
d. Support yoke and rear surface.
2. Install rack bushing to rack housing so that convex part of rack bushing lines up with slit of rack housing. Apply lithium base grease to inside of bushing.
3. Push rubber mount on until it just contacts end of housing.
4. Attach rubber mount to column. Ensure direction of insertion and the alignment are correct and the mount is aligned with end of column. If rubber mount is difficult to install, apply soapy water to inside of mount.
5. Carefully install rack in opposite direction of removal.
Fig. 14 Disassembled view of power steering gear. 1984-87 626:
6. Install pinion shaft with notch on serration positioned as shown, Fig. 14, when rack is positioned at center of rack housing.
7. Install oil seal as follows:
a. Install new snap ring. The snap ring tapered side must face upward.
b. Install stop ring.
c. Apply a coat of grease to oil seal lips.
d. Install oil seal by pushing it in by hand.
8. Attach new washers to left and right tie rods, then screw them onto rack. Ensure washer face in correct direction.
9. Torque left and right tie rods to 58-72 ft.lbs.
10. Align washer with rack groove and crimp washer.
11. Install boot, then wrap a new wire two times around it and twist it 4 or 4 1/2 times. Ensure boot is not twisted or dented.
12. Install support yoke, spacer and yoke spring. Install so that support yoke correctly contacts rack.
13. Install adjust cover as follows:
a. Apply a coat of sealant to threads of adjust cover.
b. Torque adjust cover to 29-43 ft.lbs.
c. After torquing adjust bolt to 8.7 inch lbs., loosen it 10-40°.
Fig. 13 Measuring pinion preload w/manual steering gear:
d. Measure pinion torque, Fig. 13. In neutral position ± 90°, pinion torque should be 7.81-11.28 inch lbs. with scale reading 31.7-45.9 ounces. In any other position, pinion torque should be 13.02 inch lbs. or less with scale reading 52.9 ounces or less.
e. If pinion torque is not within specifications, readjust pinion torque by adjusting adjust bolt.
f. Torque locknut to 7-10 ft.lbs. and secure with adjust bolt. Do not let adjust bolt turn with locknut.
14. Install tie rod ends, aligning match marks.
Fig. 10 Disassembled view of variable gear ratio manual steering gear. 1986-88 323:
W/Variable Gear Ratio Steering Gear
1. Before assembling, the following parts should be coated or packed with suitable grease:
a. Lower bearing.
b. Pinion bearing and teeth.
c. Inside gear housing.
d. Oil seal lip.
e. Pressure pad sliding part and rear surface.
2. Press lower bearing into housing, Fig. 10.
3. Install rack busing in rack housing using a suitable piece of wood. Ensure three bushing lock points are aligned.
4. Install mounting rubber.
5. Install rack in opposite direction of removal.
6. Install pinion shaft with rack positioned so that notch on teeth edge of rack is at center of pinion.
7. Install upper bearing.
8. Push oil seal in pinion plug, then install pinion plug with oil seal on pinion shaft.
9. Adjust pinion preload to 1.74 inch lbs. using a suitable torque wrench or to 5-9 ounces using a spring scale by adjusting pinion plug. Before measuring pinion preload, rotate pinion to left and right to seat bearing.
10. Install locknut and torque to 51-65 ft.lbs.
11. Apply a coat of suitable sealant to threads of adjustment cover, then install pressure pad, spring, adjustment cover and locknut. Ensure pressure pad is correctly installed.
12. Torque adjustment cover to 7.2 ft.lbs., then back off cover approximately 15deg. and torque locknut to 43-54 ft.lbs.
13. Measure pinion preload. When pinion is within 90° of neutral position, preload should measure .87-1.21 inch lbs. If measuring with a spring scale, preload should measure 35-49 ounces. When pinion is in any other position, preload should measure 20 inch lbs. or less. If measuring with a spring scale, preload should measure 81 ounces or less.
14. Apply soapy water to inside of rubber mount, then install rubber mount on steering column.
15. Install tie rod washers and tie rod. Torque tie rod to 58-72 ft.lbs. Align washer with rack groove, then crimp washer to secure.
16. Install dust cover on pinion groove, then the new boot and wire. Wrap wire twice around boot and twist end 4-5 times around.
17. Install tie rod end, aligning marks made during disassembly.