Assembly -
Coat steering rack - inside of cylinder end stopper and bushing, bearings, control valve assembly, rack guide spring cap, spring, and guide with molydisulfide lithium grease
Coat all O-rings, oil seals, and teflon rings with PS fluid
When installing oil seals, be sure they don't get reversed.
1. Install steering rack - special tool? - reburr and burnish teeth if necessary - be careful of oil seal lip
2. Install bushing with O-ring - tape end of rack to prevent seal damage - install bushing in correct direction - don't damage oil seal lip
3. Install cylinder end stopper - align the installation hole for the wire of the stopper with the slot of the rack housing - use new wire - turn stopper clockwise 450 +/- 50 degrees - special tool?
4. Test seals with vacuum on fittings - must hold vaccuum for 30 seconds - if bad, check oil seals
5. Install rack housing No. 2 bracket and grommet - align the projection of the grommet with the hole of the bracket - align the matchmarks on the bracket with those on the rack housing - place the bracket in a vise and use the vise to fasten the clamp
6. Install the control valve assembly into the valve housing - protect seal lip by wrapping serrated part of valve shaft with electrical tape - be careful not to damage the teflon rings and oil seals
7. Install oil seal with press - correct direction
8. Install control valve housing with control valve assembly - new gasket on rack housing - align matchmarks on valve housing with those on rack housing - torque 2 bolts to 13 ft-lbs
9. Install self-locking nut on control valve shaft - 18 ft-lbs - Install dust cover
10. Install rack housing cap with sealant on 2 or 3 threads - Locktite 242 or Three Bond 1344 - 43 ft-lbs - stake the 2 parts of the cap with punch
11. Install rack guide seat, rack guide, rack guide spring and rack guide spring cap - apply sealant on 2-3 threads of cap - temporarily install cap
12. Adjust preload - torque the rack guide spring cap to 18 ft-lbs - turn counterclockwise back 12 degrees - turn control valve shaft right and left once or twice - loosen cap until rack guide spring is not functioning - tighten rack guide spring cap until preload on control valve shaft is 6.9 - 12.2 in-lbs
13. Install rack guide spring cap lock nut - apply sealant to 2-3 threads of nut - hold rack guide spring cap and torque nut to 36 ft-lbs - recheck preload as above
14. Install new RH and LH claw washers and temporarily install rack ends - align the claws of the washer with the steering rack grooves - hold steering rack and torque rack end to 45 ft-lbs - stake the washer with brass bar and hammer - don't hit rack
15. Install RH and LH rack boots, clamps, and clips - make sure steering rack hole is not clogged with grease - be careful with boots - tighten clamp by pinching with special tool to 3 mm or less clearance on clamp ends
16. Install RH and LH tie rod ends and lock nuts - align matchmarks on rack and tie rod end - after adjusting toe-in torque to 54 ft-lbs
17. Install 2 turn pressure tubes 7 ft-lbs
18. Install steering gear from LH side of vehicle - don't damage turn pressure tubes
19. Lift up stabilizer bar and install 2 gear assembly set bolts and nuts 134 ft-lbs
20. Install HO2 sensor 33 ft-lbs
21. Connect stabilizer bar bolts (14 ft-lbs) and nuts (29 ft-lbs)
22. Connect pressure feed and return tubes 15 ft-lbs
23. Connect tube clamp with nut 7 ft-lbs
24. Connect intermediate shaft - align matchmarks on intermediate shaft and control valve shaft torque 2 bolts to 26 ft-lbs
25. Connect tie rod ends 36 ft-lbs
26. Install fender apron seals 2 bolts
27. Center steering wheel if necessary
28. Bleed PS system - jack up front of car and turn steering wheel lock to lock and hold at locks for 2-3 seconds (engine off). Check fluid level in reservoir. Lower vehicle, start engine, idle engine for a couple of minutes, turn steering wheel lock to lock and hold at locks for 2-3 seconds and repeat turn and hold several times. Stop engine and check for foaming in steering reservoir. Foaming indicates fluid leaking in system. Check fluid level
29. Check alignment
Good luck - sounds like a special-tools nightmare - seating the telfon seals with a special tool SST 09631-20081 may be critical
Get out your digital camera and take alot of photos as you go.