Currently rebuilding a fast ratio power steering box from a 89 IROC. Its been awhile since I did the one on the car now.
My question is do you reuse the big thread-in plug on the end of the piston,or do you use the plug from the original steering box?
I know the end plug of the steering box itself is the end stop and must be changed. Also the internal stop(actually 2 spring rings)are removed.

Cant wait to relive "dropping my balls" You'ld understand if you've done one

You can reuse the plug. I assume that you have an arbor to reassemble your worm into the rack. If you don't I have a sketch of the arbor tool along with several papers on rebuilding the Saginaw power gear. They are available at www.corvettefaq.com/A-Car.asp (http://www.corvettefaq.com/A-Car.asp)

The arbor sketch is #5

Here is the listing of the papers.

Saginaw RB Power Gear Disassembly & Repair Pic #1 - Replace pitman shaft seals, side cover, end plug, and rack piston repairs.

Saginaw RB Power Gear Disassembly & Repair Pic #2 - Remove, disassemble and install the adjuster plug, bearing, worm, & valve assy.

Saginaw RB Power Gear Disassembly & Repair Pic #3 - disassemble and assemble the rack piston, remove and install pitman seals and bearing.

Saginaw RB Power Gear Disassembly & Repair Pic #4 - Check valve replace, adjust thrust bearing preload and over-center sector adjustment..

Saginaw RB Power Gear Disassembly & Repair Pic
#5 - Recommended assembly torque specifications and assembly tool drawing.

Thanks Jim,
I've already got the arbor on hand from the last one I did. Did the first rebuild without using it,what a pain.
Also my first attempt at rebuilding included about 3 assembly /disassembly "tries"

What ever you do, if you drop a ball, make sure that you find it. Don't under any circumstances leave it loose inside the gear. It can lodge between the rack and the end plug. It can crack the end plug when the rack goes to full lock.

Thanks Jim, The endcap is available form GM. I oredered a new one last week so my swap out wont have to include a r & r of the endcap.