Pinion and Valve Assembly

Fig. 20 Rack Bearing Removal:

Fig. 21 Retaining Ring & Locknut Removal:

Fig. 22 Housing Reference Mark:

REMOVAL
1. Remove rack and pinion steering assembly from vehicle.
2. Remove adjuster plug locknut from adjuster plug, Fig. 20.
3. Remove adjuster plug from housing, then adjuster spring and rack bearing.
4. Remove retaining ring from valve bore of housing then, the dust cover, Fig. 21.
5. Holding stub shaft, remove hex locknut from pinion and valve assembly. Stub shaft must be held to prevent damage to pinion teeth.
6. With rack centered, mark location of stub shaft notch on housing, then measure distance "A", as shown in Fig. 22.
7. Using a suitable press, press threaded end of pinion until the pinion and valve assembly is almost removed. Mark a second location of stub shaft notch on housing. The second mark is used to position notch prior to reassembly.
8. Remove stub shaft dust seal, stub shaft seal, stub shaft bearing annulus assembly and pinion and valve assembly with retaining ring and valve body rings attached.
9. If necessary, remove valve body rings from pinion and valve assembly, then clean ring grooves. Inspect pinion and valve assembly for broken drive pin. If found, replace gear assembly.

Fig. 12 Exploded View Of Power Rack & Pinion Assembly:

INSTALLATION
1. If valve body rings are to be replaced, apply grease to ring grooves and rings and Install new rings, ensure split tabs are engaged and staggered, Fig. 12.
2. Place pinion and valve assembly into clear pinion and valve assembly ring protector tool No. 37090, or equivalent. Allow to set for at least three minutes.
3. Center rack in housing, refer to measurement "A" taken during disassembly.
4. Wipe housing bore clean and apply grease to valve housing bore. Inspect stub shaft bearing annulus for damage and ensure bearing is flush with annulus.
5. Align notch on valve stub shaft with second mark on housing made during disassembly.
6. Install pinion and valve assembly with spool shaft retaining ring and valve body rings installed into housing using clear pinion and valve assembly ring protector tool No. 37090, or equivalent, to prevent ring damage.
7. Install pinion and valve assembly onto rack using clear pinion and valve assembly ring protector tool No. J 37090, or equivalent, and pinion seal installer tool No. J 29822, or equivalent. Do not hammer or use excessive force.
8. Ensure notch in stub shaft and first mark on housing are lined up while rack is centered in housing. Refer to measurement "A" taken during disassembly.
9. Hold valve stub shaft and thread hex locknut into pinion, then torque to 26 ft lbs. If stub shaft is not held, damage to pinion teeth will result.
10. Install dust cover onto housing.
11. Install stub shaft bearing annulus assembly onto valve stub shaft.
12. Place seal protector tool No. J 29810, or equivalent, onto valve stub shaft, then apply a small quantity of grease between stub shaft seals.
13. Install stub shaft seal and stub shaft dust seal over protector and into housing.
14. Install retaining ring into groove in housing.
15. Lubricate stub shaft and dust seal area, then coat rack bearing, adjuster spring and adjuster plug with lithium grease and install in housing.
16. With rack centered in housing, turn adjuster plug clockwise until it bottoms in housing, then back off 50 ° to 70 °. Check tightness on pinion. Maximum pinion preload torque is 16 inch lbs.
17. Install adjuster plug locknut to adjuster plug, then tighten firmly against housing while holding adjuster plug stationary.
18. Install rack and pinion assembly, then flush power steering system.