LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Mazda >> 1978 >> Cosmo Standard Trans >> Repair and Diagnosis >> Steering >> Steering Linkage >> Power Steering - Power-Assisted Recirculating Ball >> Overhaul >> Steering Gear Assembly
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Steering Gear Assembly

  1. Lubricate and install "O" ring in valve housing. Insert worm shaft into piston so that three grooves are visible between valve housing and ball nut, then place 19 balls into hole near Teflon ring as worm is turned clockwise. Insert remaining seven balls into one side of ball guide, hold in place with Vaseline, then position other half of ball guide over balls and install in piston.
  2. Apply Vaseline to new "O" ring and install on cover. Make sure neoprene pad is in cover, then position cover on ball nut and tighten attaching screws to specification. Use a straightedge to make sure guide cover head is not higher than Teflon ring. File off high spots.
    NOTE: Do not rotate piston or stub shaft after balls are inserted, as balls may fall out of circuit.
  3. Coat new "O" ring with Vaseline and install in pressure port of gear housing. Coat Teflon seal with Vaseline and install on piston, then insert piston and valve into gear housing. Align lube passages in valve housing with passages in gear housing and install, but do not tighten, attaching bolts.
  4. Rotate ball nut until teeth mesh with sector teeth then tighten valve housing bolts to specification. Insert side cover "O" ring in steering gear housing, then turn stub shaft to center the piston. Screw side cover onto adjusting screw until it bottoms, then back out one and one half turns.
  5. Lubricate sector shaft bearing and journal, then install sector shaft with center gear tooth meshing with center groove of rack piston. Install side cover attaching bolts and lock washers and tighten to specification.
    NOTE: Make sure cover "O" ring is in place before tightening bolts.
  6. Turn stub shaft completely to left or right, then back 90°, then using pull scale, recheck that initial preload is to specifications. Turn sector shaft adjusting screw to adjust final preload to specifications. Install new rubber seal and adjusting screw lock nut, then tighten lock nut to specifications. Align identification marks and install pitman arm on sector shaft and tighten nut to specifications.
scientia non olet · About LEMON Manuals