Ford Corsar Repair Manual page 714

MANUAL STEERING GEAR AND LINKAGE (TRW)
8. With the rack in the straight ahead position, install yoke and
yoke spring. Install yoke plug, and using special tool
No. E8802-1 tighten to 4.5 Nm then back off 15-25 degrees.
9. Tighten yoke plug lock nut (using Tool No. E8802-2. Yoke plug
must be restrained from turning during this operation.
IMPORTANT: Once yoke clearance has been set gear must be
racked
from
lock to lock to ensure wear has not appeciably
M e d setting, gear should not bind or appear-tight over any
part of the
total travel. Should gear bind or excessive free play
appear, adjust yoke plug. If this is not the cause, strip gear
and examine rack and pinion for wear and damage.
10. Fill the internal lip cavity of the pinion seal with grease and fit
the seal over the pinion shaft into the top of the pinion plug.
1 1. Assemble ball housing to rack, then using special tool (Litch-
field No. E8802-6) torque to 80-88 Nm. (Using Special Tool,
Torque Wrench will read 47.5 Nm.).
CAUTION: When torquing use an adjustment wrenchon the flat
teeth of the rack to prevent rack rotation and possible damage
to rack or pinion teeth. Be careful not to nick or damage rack on
yoke side.
12. Drill a 4 mm dia.
X
10 mm deep hole into the rack adjacent to
each ball housing at 90" to the rack teeth.
13. Drive a 4 mm dia.
X
10 mm long pin into each hole.
14. Smear a small quantity of grease in the groove on each tie rod
where the sealing boot seats. Assemble boots and clips ensur-
ing the outer clip is accessible when the steering rack is fitted to
the vehicle.
ST- 1 7