Instruction Sheet
INSTRUCTION SHEETFOR EFFECTIVE REPAIR, USE ALL PARTS IN KIT REGARDLESS OF ORIGINAL CONDITION.
SERVICE PROCEDURE FOR INSTALLING "SPECIAL" VALVE BODY RINGS ON RACK AND PINION ASSEMBLIES WITH HARD STEERING ON INITIAL START-UP
READ INSTRUCTIONS COMPLETELY AND CAREFULLY BEFORE PROCEEDING.
Some complaints about the power steering system on initial start up may be reported as:
^ Reduced power steering assist when parking.
^ Increased steering effort.
For further information, refer to the "Steering Diagnosis" section in vehicle service manual.
Tools Required:
J 37090 Pinion and Valve Ring Protector J 29822 Pinion Seal Installer J 29810 Stub Shaft Seal Protector
A. Remove rack and pinion assembly from car.
Figure 1 - Rack Bearing Removal:
Figure 2 - Retaining Ring and Lock Nut Removal:
B. Valve removal:
1. Remove adjuster plug lock nut from adjuster plug.
2. Remove adjuster plug from housing.
3. Remove adjuster spring, rack bearing and O-ring if required.
4. Drain power steering fluid from gear. (Rotate stub shaft allowing rack to travel corner to corner for removal.)
5. Remove retaining ring from housing.
6. Remove dust cover from housing.
7. While holding the stub shaft, remove lock nut from pinion.
vImportant
If stub shaft is not held, damage to the pinion teeth will occur.
Figure 3 - Housing Reference Mark (Typical) and Rack Centering Measurement:
8. With gear centered, mark location of stub shaft flat or notch on housing and measure distance "A" indicated in Figure 3 for your specific vehicle; this will aid in proper reassembly.
Figure 4 - Pinion and Valve Removal:
vImportant
DO NOT hammer or pound on pinion and valve assembly, this could cause damage or loosen the drive pin.
9. Use an arbor press to press on threaded end of pinion until it is possible to remove the pinion and valve assembly from housing. Just before removal of pinion and valve assembly from housing, mark second location of stub shaft flat or notch on housing. The second mark is used to position flat or notch prior to reassembly.
Figure 5 - Ring, Seal and Bearing Removal:
10. Remove stub shaft dust seal, stub shaft seal stub shaft bearing annulus assembly, pinion and valve assembly, with spool shaft retaining ring. and valve body rings attached.
11. Remove valve body rings from pinion and valve assembly.
vImportant
Use care when removing rings from valve assembly to prevent damage to valve assembly.
Figure 6 - Drive Pin Inspection:
12. Thoroughly clean valve assembly ring grooves.
Inspect
v Inspect pinion and valve assembly for broken drive pin. If broken drive pin is found, replace the gear assembly.
v Important
Use the same Housing and Valve Assembly regardless of depth of grooves in housing bore.
Figure 7 - Valve Body Ring Installation:
C. Install now split rings onto the valve assembly as follows:
v Important
Valve assemblies and housings are NOT interchangeable. The same valve assembly MUST be reinstalled or rack and pinion asembly must be replaced.
vImportant
Apply a liberal quantity of grease supplied in kit, in each ring groove and to new valve body rings when installed to hold rings in position. (See Figure 7.)
1. Install new valve body rings to pinion and valve assembly. (Care must be taken not to cut rings at installation.)
Figure 8 - Ring Setting Procedure:
2. Place pinion and valve assembly into clear pinion and valve assembly ring protector J 37090. (Be sure to use only the dear protector.) Allow to set for approximately three minutes while continuing installation preparation. This allows the valve rings to be properly sized.
3. Position valve assembly in protector so that valve body is flush with bottom of clear protector. (See Figure 8.)
v Inspect
Inspect valve body rings for cuts, nicks or other damage, proper seating of rings in grooves and engagement of split tabs.
Figure 3 - Housing Reference Mark (Typical) and Rack Centering Measurement:
4. Rack must be centered in housing. (See Figure 3 on page 2.)
5. Wipe housing bore clean of any foreign material.
Figure 9 - Housing Bore Preparation:
vImportant
Apply a liberal quantity of grease to the valve housing bore. Be sure to fill grooves with grease. This will ease reassembly of valve into housing.
Figure 10 - Bearing and Annulus Inspection:
v Inspect
Inspect stub shaft bearing annulus for flatness and damage. Clean before reassembly.
Figure 11 - Pinion and Valve Installation:
6. Align stub shaft flat or notch with second mark on housing made during disassembly. (See step 9 on page 2.) Install pinion and valve assembly with spool shaft retaining ring, and valve body rings included, into housing using J 37090 to prevent damage to valve rings during assembly.
v Important
Set pinion and valve assembly onto housing using J 37090. Use J 29822 pinion seal installer to push assembly into housing bore. DO NOT hammer or use excessive force. If pinion and valve assembly does not fully seat in housing, check to be sure valve body rings are not binding in housing bore. Check rings for cuts or damage. Repeat installation steps 1 through 5. If pinion and valve assembly will not align properly in housing bore, replace rack and pinion assembly.
Figure 3 - Housing Reference Mark (Typical) and Rack Centering Measurement:
v Inspect
When pinion and valve assembly is fully seated, flat or notch in stub shaft and first mark on housing must fine up while the rack is centered in the housing. Refer to measurement "A" to verify proper rack position. (See Figure 3.)
Figure 12 - Seal Installation:
Figure 14 - Rack Bearing Installation and Adjustment:
7. While holding the stub shaft, thread lock nut onto pinion and torque to 35 N-m (26 Lbs.Ft.).
vImportant
If the stub is not held, damage to the pinion teeth will occur.
8. Install dust cover to housing.
9. Install stub shaft bearing annulus onto stub shaft.
10. Place seal protector J 29810 onto stub shaft.
11. Install stub shaft seal and stub shaft dust seal over protector and into housing. (Apply a small quantity of grease between seals and on top of dust seal.)
12. Install retaining ring into groove in housing.
13. Coat rack bearing, adjuster spring and adjuster plug with lithium base grease and install in housing. (See Figure 14.)
v Adjust
With rack centered in the housing, turn adjuster plug clockwise until it bottoms in the housing, then back off 50~ to 70~ (approx. one flat). Check torque on pinion. Maximum pinion preload torque is 1.8 N-m (16 Lbs.In.).
14. Install adjuster plug lock nut to adjuster plug. Tighten firmly against housing while holding adjuster plug stationary.
15. Install rack and pinion assembly into car. (Use appropriate service manual.)
v Important
Flush power steering system (boses, reservoir and cooler lines) with power steering fluid - GM Part #1050017 (or equivalent meeting GM Specification #9985010). Disconnect return line at pump reservoir. (Refer to bleeding procedure in vehicle service manual.) Be sure pump reservoir fluid level is maintained during the flush procedure.
16. Reconnect return line at pump reservoir.
17. Fill with power steering fluid.
18. Bleed air from system.
vInspect Inspect for leaks.
19. Check toe angle and reset if necessary.