Genuine Mazda RX-7 Rack and Pinions

Mazda RX-7 Rack and Pinions Parts and Q&A

• Steering Gear
  FA24-32-110B
  Q: How to remove and install the rack and pinions in the steering gear assembly on Mazda RX-7?

  A:

  The rack and pinion system is a unitary system incorporating the steering box underneath the vehicle and a continuous steering shaft running through the steering column to the Steering Wheel, which is often a lengthy and even a bit challenging operation that is only undertaken when there is a lot of mileage on it or to correct damage caused during a frontal collision. Start with removing the battery negative cable then move into the car removing the horn cap. Prior to removing the steering wheel, place identification marks on the steering column shaft and steering wheel to be correctly reinstalled without causing any damage to the steering column shaft end. Once the steering wheel has been removed, loosen the steering column covers, disconnect the air duct beneath the dashboard and disconnect the electrical couplers. Then take off the stop, cancel, and spring at the end of the steering column, slip the combination switch assembly and take out the steering lock assembly. Tape the steering lock hole on the column shaft to avoid leakage of lubrication and remove the four bolts at the column jacket fixing brackets. Identify the points of the hinges of the hood hinges and take out the hood, raise the front side of the car and hold up using jack stands. Loose the center link to the Pitman Arm with a gear puller and then take off the Pitman arm on the sector shaft. Loose the rack and pinion housing attaching bolts that hold the steering box to the frame rail and remove the rack and pinion assembly via the engine compartment, keeping a record of the locations of any shims between the steering box and frame. To install, position the steering box in place with any positioning shim necessary, screw the attaching bolts to the frame, install the Pitman arm to the sector shaft making sure the arm is in the center of the adjustment, and attach a dial indicator and adjust the lock nut on the adjusting screw. Attach the center link to the Pitman arm and screw the lock nut and replace a new cotter pin. Reduce the vehicle, replace the hood with the identified hinge points and complete the assembly of all the units in the steering column, leaving out the tape at the steering lock hole and employing the identification marks at the steering wheel installation. Last but not least, re-attach the negative battery cable and pour gear lubricant; SAE 90.
• Steering Gear
  FD15-32-110B
  Q: How to overhaul a steering gear with Rack and Pinions on Mazda RX-7?

  A:

  First, get a rack and pinions overhaul kit which contains small parts needed to disassemble. Drain the steering box, replace the rack and pinions housing in a vise with the adjustment screw upward, and cushion with wooden blocks. Take off the column jacket on the column shaft followed by loosening the adjusting screw lock nut and removing the three bolts of the side covers. Turn the screw of adjustment clockwise and remove the side cover and take care to deem the sector shaft out of the housing and be careful not to disturb its position. Unscrew the large lock nut at the bottom of the worm shaft, which can be done with a large box wrench, unscrew the end cover and take out the worm shaft and ball nut assembly without breaking them down. Check the oil seal and change only when required, and make sure that there is a smooth running of the ball nut assembly on the worm shaft; failure to do so necessitates replacement of the entire rack and pinions assembly. Inspect the worm bearings for wear or damage of the worm cups and change the gear assembly in case of any problems. Measure the final clearance between the sector shaft and adjusting screw using a feeler gauge and replace the assembly in case it is greater than the specified limit. Equally, test the clearance between the sector shaft and the housing bore and replace the assembly where it is greater than the check. Check the oil seal and see whether it is damaged or worn out, and place a new seal in place so that it does not leak. Install the worm shaft and ball nut assembly back into their starting positions, and screw the end cover until the preload of the worm shaft is within the specified range, which is measured using a spring scale on the worm shaft. Install the rack adjusting screw and shim to fit into the slot of the sector shaft, install the worm shaft rack, then position the adjusting screw and shim in the sector shaft slot and make sure it fits into the worm shaft rack. Put a thin layer of silicone sealer on the side cover and place it on the adjusting screw, and turn it in a counterclockwise direction to fasten. Install the mounting bolts of the side cover, momentarily tighten the adjusting screw lock nut, and lastly install the column jacket over the column shaft and then adjust the rack and pinions.