Steering Gear: Reassembly

Install seal and "O" ring to right side rack sleeve. Seal lips should face down. Lubricate seal lips before installation and use a socket to press in.
Install "O" ring and Teflon ring to piston seal. Install seal ring in pinion housing with Handle and Drift (1801 and 5184 ). Seal ring lip must face up.
Ensure bearing turns freely on pinion shaft. Install to pinion housing with handle and drift. Fit spacer washer from the rack toothed side. Cover rack teeth with tape and lubricate with automatic transmission fluid.
Install seal with lips facing inward. Install tapered spacer washer with taper facing seal ring. Install second spacer washer. Remove tape and push 2 spacer washers together.
Fill rack teeth with lubricant (Volvo P/N 1 116 001-1). With teeth facing up, insert rack into tube. As seal ring enters tube, apply pressure on rack.
Seal ring and distance washers will lock into position in tube. Looking through inner high pressure hole, line up Teflon ring with center of hole.
Pull rack rod back until it is positioned flush with pinion housing left side. DO NOT pull rack further back. Cover threads and edge of rack with tape.
Install rack sleeve with seal facing to the right. Take care not to damage sleeve outer "O" ring against lock wire groove. Install plastic spacer in rack with bevelled edge toward seal.
Remove tape. Place sleeve on rack with recess facing steering rod end. Turn sleeve to line up hole in lock sleeve with elongated hole in tube.
Using a new lock wire, install wire in lock wire groove. Slowly turn sleeve counterclockwise until end of locking wire is positioned inside elongated hole in tube.
If removed, install inner race for pinion lower bearing. Pack pinion gear with lubricant. Install rack rod in housing.
With pinion in place, rack should protrude 2 1/8" (55 mm) from housing when flat of lock bolt is in positions shown. See Fig 1 .

Fig 1: Positioning Rack Rod Pinion Pinion gear should be filled with grease.

NOTE: Be careful when installing pinion not to damage valve.
Use Pinion Bearing Sleeve (5049 ) to screw on inner bearing. Shaft end should protrude 23/64" (9 mm). Install outer race for lower pinion bearing.
Install spacer sleeve on top of bearing race. Screw in sleeve until it bottoms. Place lock washer in position on housing and finger tighten bolts.
Bend down lock washer tab which is lined up with one of the recesses on sleeve. Remove bolts and washer. Install "O" ring in lower part of valve housing.
Install valve housing, being careful not to damage housing or pinion valve. Install coil spring with large end facing down. Using cover Installing Sleeve (5182 ) place "O" ring in position.
As cover is installed, ensure that coil spring is not squeezed under cover. Install dust seal. Install lock washer and nut. Use Pinion Shaft Socket (5179 ) to hold pinion when tightening nut. Do not lock with washer tab.
Measure preload piston clearance. Place piston without "O" ring in housing. Measure clearance between piston and housing. Use a feeler gauge and ruler.
Press piston against rack while sliding rack back and forth. Note maximum clearance. Select shim with thickness .002-.006" (.05-.15 mm) greater than thickness noted in step 18).
Place spring in position. Install shims and gasket, with gasket closest to aluminum housing. Install cover and tighten. Measure pinion torque with pinion shaft socket and Torque Gauge (9177 ).
Move rack back and forth between rack end positions. Correct torque should be 8-15 INCH Lbs. (.9-1.7 N.m). If torque in any position is excessive, stop rack in that position and readjust preload.
If rack binds with preload removed, rack is warped and must be replaced. Use a spanner on ball joint and support rack end with a large adjustable wrench to install steering rods.
Lock steering rods in rack recess using a narrow punch. Remove steering gear from holding fixture. Fill rubber boots with approximately 3/4 ounce of lubricant.
Install boots and equalizer tubes at the same time. Install plastic clamps on boots. Secure equalizer tube with strip clamp. Install 2 high pressure lines.

If removed, lubricate needle bearing with lubricant (Volvo P/N 1 161 001-1). Install to pinion housing with drift. Bearing bottom should be flush with housing.
Install bearing race (bevelled edge down), needle bearing and bearing race to pinion housing. Do not use lubricant at this time. See Fig 1 .

Fig 1: Installing Pinion Bearings and Races Race is installed with beveled edge down.

NOTE: Before installing any seals, preload of pinion bearing must be checked.
Install pinion assembly without seals. Install bearing, race and spacer washer to pinion. See Fig 1 . Install pinion housing cover. Tighten cover bolts to 7 ft. lbs. (10 N.m).
To adjust pinion, tie a string around shaft. Attach a spring gauge and measure turning force. Force should be 3.7-6.4 lbs. (1.7-2.9 kg). Adjust by replacement of spacer washer. See Fig 1 .
Washers are available in increments of .0004" (.01 mm) from .075" (1.91 mm) to .10" (2.45 mm). Remove pinion with bearings and spacers.
Install 4 rubber "O" rings in valve body grooves. Install 4 Teflon rings over "O" rings.
NOTE: Green Teflon ring must be installed as indicated by arrow in Fig 2 .
Install pinion housing seal in housing with lips up. Fill lubricant in space between seal lips. Use drift and handle to install.
Install spacer ring to housing with cone end in, grooved end out. Install bronze bushing in spacer (inner) tube with chamfered side down.

Fig 2: Installing Green Teflon Ring to Pinion Ring must be installed at arrow.
Fill lubricant in space between seal lips and install seal in spacer tube with lips up. Use drift and handle. If removed, install replacement spacer washer and lock ring to tube (only if removed).
Install lock ring with notch (for wrench) facing center of tube. Smear threads and lock ring with lubricant. Install "O" ring. Lubricate Teflon bushing with ATF and install. Install spacer.
Grease seal lip and install with lip facing up. Use Drift (5184 ) and Adapter (5269 ) with extension pieces and install. Install Teflon ring and "O" ring to tube. Fill snap ring grooves and coat surrounding area with wheel bearing grease.
Slide tube into steering rack from smooth end and pass quickly over snap ring. Install "O" ring and piston ring to piston. Collar threads should be lubricated before installation.
Adjust steering rack so it protrudes 2 1/16" (53 mm) from edge of housing. Fill pinion teeth with lubricant. Install bearing washer with bevelled edge down.
Attach thrust washer and thrust bearing to valve body with grease. See Fig 2 . Hold pinion with flat surface in line with upper high pressure outlet and insert to housing.
As the pinion enters housing, it will turn. When fully seated, the flat surface should be parallel to flat surface of housing. Rack must not have moved. Install bearing, race and spacer washer of predetermined thickness. See Fig 2 .
Fill top cover seal lips with lubricant. Install seal on Drift (2863 ) with seal lips toward drift. Remove screw and cone. Tap seal in cover. Oil "O" ring with automatic transmission fluid and install.
Install cover on Sleeve (5182 ), with cone attached. Remove cone. Install cover. Tighten bolts. Install dust seal. Insert preload piston without "O" ring.
Be sure Teflon insert is on piston. Set up Preload Measuring Fixture (5865 ) using cover bolt hole and a 8 x 45 mm bolt. Assemble Fixture with the preload spring between bolt head and bolt. Adjust for slight preload.
Move gear lock-to-lock an ensure it does not jam. With micrometer measure distance between housing face and piston stop. Check measurement at 3 different points on steering rack. Subtract .004-.006" (0.1-.15 mm) from smallest reading obtained. Select washer of that thickness.
Washers are available in thickness of .083-.114" (2.1-2.90 mm) in increments of .0019" (.05 mm). Remove Press (5865 ). Lubricate "O" ring and install on preload piston. Install spacer washer and piston spring.
Fill space around spring with lubricant. Apply sealant on cover sealing surface. Install and tighten cover. Install and tighten pressure lines. Ensure "O" rings seat correctly.
Install steering rods. Bend back steering rod locks. Install boots. Fill each boot with approximately 3/4 ounce of lubricant. Install boot clamps. Install equalizer tube and plastic clamps.