STEERING AND FRONT SUSPENSION Rack and Pinion
2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 7-9
7
RACK AND PINION ASSEMBLY
1. Apply a liberal amount of EP grease to the teeth of the rack (2), then slide the rack through the bushing
(17) and housing (1) (Figure 7-20, Page 7-11).
CAUTION
• In step 2, do not press against the outer race of the bearing.
2. If the pinion bearing (15) was removed, grease a new bearing before installation. Press new bearing onto
pinion shaft, exerting all pressure on the inner race. Then install the c-type stop ring (16). See previous
CAUTION.
3. Install pinion (3) and bearing (15) assembly into the housing (1). Make sure the rack gear teeth will mesh
with the gear teeth on the pinion. The rack may need to be rotated slightly while lightly tapping on the pin-
ion-bearing assembly with a rubber mallet. See following CAUTION.
CAUTION
• Do not force the pinion-bearing assembly into the housing. The gear teeth or the small bearing
could be damaged.
Figure 7-16 Remove Pinion Figure 7-17 Remove Pinion Gear Assembly
Figure 7-18 Remove Rack Figure 7-19 Remove Ball Joint
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