finished up the rack this week..
so I had to buy a slide hammer pilot bushing puller to get the inner bearing out of the rack housing.. that bearing was really bad, the water in the housing really killed the bearing
If you remember the bearing you can get are 1mm too narrow to work, so I had to find or make a spacer. several folks have mentioned that a valve shim would work.. I dug around in my stuff and looked for something I could use or modify, and lo and behold I found the perfect washer ! 15mm id .035 thick ( close enough to 1 mm for me ! )
I installed two of them between the pinion and the bearing ( otherwise you cannot install the pinion if it is on the other end, it fouls with the rack. )
after I installed the pinion with the spacers, I set up a dial indicator to determine how much axial play the pinion and its bearings had, Ideally one would have a bunch of the shims so you could get a just .002 free play or so .. I only had 3 shims.. played with it until I got what I think is a few thousands of preload. I measured .002 with the bearing housing and shims in place but not torqued. after I tightened the bolts the free play disappeared. no play but it still turned easy
the shop manual specifies checking the turning torque. so I checked it with a small dial torque wrench rigged with a steering spline piece, It was within specs.
I then installed the rack and the mesh adjustment shoe ( had to work the shoe with a bit of sandpaper to get it to move freely in the bore ) . adjusted the preload while taking torque measurements. ( never quite understood why there are shims under the spring, I just adjusted the positioned the big screw cap and locked the jam nut ? ) . got the torque within spec, but it always had a tight spot on one side of the travel.. not even torque all thru the travel.
installed the inner tie rods, installed a grease nipple and pumped them full of grease , they felt good with no real play and did not flop around
installed the boots with tye wraps and all done ! ( I also painted the housing before I put the boots on ! gotta look good ! )