7 tooth steering gear help

[George Goodridge]

I have a 29 phaeton with a 7-tooth steering gear. I was rebuilding the lower worm and sector, but they look in good shape, so I kept the worm and the sector shaft. I followed the instructions in the Les Andrews book and got as far as the end play adjustment for the steering sector. The steering shaft has little end play after putting in some shims. The shaft meshed well with the sector shaft, but the area of mesh contact seems far too small. .
The problem is the steering sector. When I install the sector including the thrust washer there is about 3/8 inch end play. I have adjusted the steering thrust screw as far down as possible, but it makes no contact. I added another thrust washer, and the end play still is huge. No contact at all with the thrust screw plate.
Also, the housing cover (marked A 3580) seems to have the angled threaded hole for the thrust screw at the wrong angle for the end of the sector shaft. The plate does not match the sector face. Is that correct?
I am not new at this and have rebuilt 2 tooth assembles several times. This one has me stumped. I believe the car had lots of steering slop when I last drove it, but it was several years ago. What am I doing wrong? Help.

 

[Joe K]

You (or someone) haven't "flipped" the cover that covers the sector have you? The cover is installed with the "proud" side towards the sector. The "concave side" goes on the outside.

Discounting the thrust screw tapping, the cover is left-right identical (as you look at it) so it technically is possible to be installed "inversed."

Joe K

 

[Joe K]

The steering shaft has little end play after putting in some shims.

The shaft is NOT the worm. A little "up-down" is permissible of the steering wheel shaft. But its the worm position/movement which determines any "free-motion" of the sector.

I did my two on the bench using paper shims that come in the kits. As I said I SUBTRACTED shims to "tighten up" the free motion of the worm (and reduce worm lateral/up-down to essentially zero) until the worm started to "turn hard" with the steering shaft/wheel. Then put back in the thinnest paper shim I had to achieve a "easy turn with minimal sector movement" condition.

Joe K