Ford Corsar Repair Manual page 713

MANUAL STEERING GEAR AND LINKAGE (TRW)
9. Using special tool (Litchfield No E7 1 10- 1 )remove pinion plug.
10. Remove pinion and rack.
1 1. Invert housing and draw out lower pinion bearing by hand.
12. Remove left hand rack bush from tube and discard.
Inspection
Thoroughly clean and dry all parts.
Check rack for signs of tooth wear, tooth contact and signs of
irregular wear pattern. Check for scoring at yoke and bush
contact areas.
Check pinion for signs of tooth wear and irregular contact.
Inspect pinion bearing for nicks, scores and signs of brinelling.
NOTE: Pinion and bearing should not be separated. Damage
or wear to either requires replacement of the assembly.
Check steering gear housing for scoring wear and damage.
Assembly
1
.
Place steering gear in a soft jawed vice or suitable fixture
2. Fit left hand rack bushing with a suitable piece of tube, ensuring
tabs on bushing are correctly located in housing grooves.
3. Lubricate the lower bearing assembly with EPLl grease and
insert into the housing.
4. Apply approximately 3 0 cc of EPLl grease in the bottom of the
pinion bore.
5. Apply approximately 10 cc of EPL1 grease to the rack teeth and
insert rack into housing from pinion end, aligning the rack teeth
with the pinion bore. Locate rack so that it protrudes an equal
amount each side of the housing.
6. Lubricate pinion and pinion bearing and insert pinion into mesh
with the rack.
7. Apply Loctite 242 to pinion plug and install into pinion housing.
Torque to 40-50Nm several times. Back off and tighten until
there is no end play in the pinion, then tighten a further 12-24
degrees.
ST- 1 6