Rack And Pinion Installation - Pioneer 1200 Maintenance Service Manual

7
STEERING AND FRONT SUSPENSION
Rack and Pinion Assembly, Continued:
4. Install the snap ring (4).
5. Use a socket to apply pressure evenly and press in a new dust seal (Figure 7-21, Page 7-12).
6. Apply a small amount of grease to the rack guide (5) where it comes into contact with the rack (2)
(Figure 7-20, Page 7-11).
7. Install the ball joints (9) onto the rack (2) by securing the rack in a vise using wood blocks between the
rack and the jaws of the vise to protect the rack from damage. Tighten the ball joints to 60 ft-lb (81 N·m).
8. Tap a flange into the notch on the rack (Figure 7-24, Page 7-12).
9. Place a few drops of Loctite 222 to the threads of the screw (7).
10. Install the rack guide (5), pressure spring (6) and screw (7). The screw should be threaded-in until it bot-
toms out and then backed out 1/4 turn (Figure 7-22, Page 7-12).
11. Insert a 3/8-inch, 1/4-drive, deep-well socket into the steering column end of the universal joint (2) and
tighten the bolts (1) to 15 ft-lb (20.3 N·m) (Figure 7-23, Page 7-12).
12. Use a torque wrench connected to the 3/8-inch deep-well socket to measure the resistance of the rack
and pinion. Rotational resistance should measure 7 to 15 in-lb (0.8 to 1.7 N·m).
13. If measured resistance is not 7 to 15 in-lb (.8 to 1.7 N·m), adjust the screw (7) until correct setting is
achieved. Tighten the nut (8) to 28 ft-lb (38 N·m) (Figure 7-22, Page 7-12).
NOTE: When tightening the nut (8) make sure the screw (7) does not change adjustment (Figure 7-22,
Page 7-12).
14. Install the ball joints (23) to each end of the drag links (19). Tighten to 20 ft-lb (27 N·m) (Figure 7-20,
Page 7-11).
15. Install the two dust seal bellows (10).
16. Install new bellows clamps (wire ties) (11).
17. To minimize corrosion, apply a light coat of anti-seize lubricating compound to the ball joint threads.
18. Install the two nuts (12) and drag links (19). Tighten drag link (19) against nut (12) to 20 ft-lb (27 N·m)
(Figure 7-10, Page 7-7 and Figure 7-20, Page 7-11).
19. Apply a light coat of anti-seize lubricating compound to the drag link threads.
20. Install the two nuts (12) and ball joints (23) to the drag links (19). Tighten to 20 ft-lb (27 N·m) (Figure 7-20,
Page 7-11).
21. Apply a light coat of anti-seize lubrication to the universal joint and install it onto the pinion shaft and
tighten the bolt to 15 ft-lb (20 N·m).

RACK AND PINION INSTALLATION

1. To minimize corrosion, apply a light coat of anti-seize lubricating compound to the splined portion of the
steering column universal joint.
2. Align the flat portion of the shaft (1) spline with the bolt hole in the upper universal joint and then slide
the shaft into the universal joint. Install the bolt (27) and lock washer (3) and tighten to 15 ft-lb (20.3 N·m)
(Figure 7-3, Page 7-2).
3. Position the steering rack and pinion assembly on the vehicle frame, sliding the steering universal joint
up and through the hole in the mounting plate. Install the bolts (20), washers (21) and nuts (22). Using
a crisscross pattern, tighten the four nuts to 20 ft-lb (27.12 N·m) (Figure 7-20, Page 7-11).
4. Install remaining bolt and lock washer on the upper universal joint and tighten to 15 ft-lb (20 N·m).
5. Check all universal joint bolts for proper torque of 15 ft-lb (20 N·m).
6. Adjust the toe-in. See Toe-in Adjustment on page 7-13.
Page 7-10 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual
Rack and Pinion