Steering System - Manual: Overhaul: Reassembly

Place gear housing in a vise with worm shaft bore horizontal and sector shaft cover opening facing upward. Using appropriate installer, replace worm shaft bearing race in housing. Install bearing race in worm bearing adjuster.
Place upper ball bearing over worm shaft. Install worm shaft and ball nut assembly into housing and up through upper ball bearing race. Install bearing and retainer in worm bearing adjuster.
Install worm bearing adjuster in housing. Tighten worm bearing adjuster until a very slight amount of worm shaft end play exists. Install sector shaft adjuster screw and shim in "T" slot in end of sector shaft.
Using feeler gauge, check end play in "T" slot between adjuster screw and sector shaft when holding adjuster screw upward. Clearance should not exceed .002" (.05 mm). If clearance exceeds specification, install a different thickness shim.
To lubricate gear, rotate worm shaft until ball nut is near end of travel. Pack as much chassis lube grease as possible into housing without losing it out sector shaft opening. Rotate worm shaft until ball nut is near other end, and apply more chassis lubricant.
Rotate worm shaft until ball nut is at center of its travel. Install sector shaft assembly so center tooth of sector teeth enters center tooth space in ball nut.
Apply more chassis lubricant in housing. Install cover gasket. Coat sector shaft adjuster screw with a non-hardening thread sealant. Install sector shaft cover over sector shaft adjuster screw.
Turn adjuster screw until sector shaft cover almost contacts gasket. Install cover retaining bolts finger tight only. Turn sector shaft adjuster screw until sector shaft cover is tight against gasket, then loosen 1/2 turn. Loosely install a NEW lock nut on adjuster screw.
Lightly lubricate all seals with grease. Wrap sector shaft treads with single layer of tape. Install sector shaft seal in housing. Remove tape. Install worm shaft seal. Ensure seals are fully seated.
Tighten sector shaft cover bolts to specification. Adjust worm bearing preload and over-center preload. See WORM BEARING PRELOAD and OVER-CENTER PRELOAD under ADJUSTMENTS.