Saginaw Rack & Pinion Power

Fig. 1 Exploded view of Saginaw power rack & pinion steering gear:

Fig. 2 Removing tie rod from rack assembly:

1. Mark position of tie rod end on tie rod, then loosen jam nut and remove tie rod end.
2. Remove jam nut, then using pliers to expand outer bellows clamp, remove clamp from bellows. An outer clamp is not used on 1983 vehicles. To prevent damage to the bellows when removing it, note the following. Slide the small end of the bellows towards the rack until the groove is exposed. Place a small rubber band in the groove, then slide the small end of the boot over the rubber band and off the threaded end of the tie rod.
3. Cut inner bellows clamp, then remove clamp from gear.
4. Mark breather tube location, then remove bellows from gear housing.
5. Remove shock dampener ring from tie rod housing and slide ring back on rack.
6. Using a wrench to prevent rack from turning, place a wrench on tie rod housing flats and turn housing counterclockwise until tie rod assembly separated from rack.
7. Loosen adjuster plug locknut, then turn adjuster plug counterclockwise to remove plug from housing. Remove spring and rack bearing from housing bore.
8. Remove retaining ring from stub shaft.
9. Remove pinion shaft locknut dust cover.
10. While holding stub shaft in place, remove locknut from pinion shaft. If stub shaft is not held in place while removing locknut, damage to pinion teeth may result.
11. If only stub shaft seals are to be replaced, using a press, press on threaded end of stub shaft until shaft is flush with ball bearing assembly. Complete removal of valve and pinion assembly is not necessary to replace stub shaft seals.
12. To remove valve and pinion assembly, rotate stub shaft until rack is centered in housing, with pinion fully engaged. Mark position of stub shaft flat on housing for reassembly. Using a press, press on threaded end on pinion shaft until it is possible to remove valve and pinion shaft assembly.
13. If necessary, remove valve body seal rings.
14. Insert a suitable punch into access hole and remove bulkhead retaining ring.
15. If only bulkhead, bulkhead Of-ring seal or bulkhead rack seal are to be replaced, remove cylinder lines and plug both cylinder line holes in cylinder using two M12 x 1.25 bolts, tighten bolts finger tight. Position drain pan under gear, then rotate stub shaft to move rack toward right stop to force bulkhead out of housing. If inner rack seal or piston ring are to be replaced the rack must be removed from the housing.
16. Remove rack from housing, then remove piston ring from rack.

Fig. 3 Removing inner rack seal:

Fig. 4 Removing pinion lower bearing:

Fig. 5 Removing & installing upper pinion bushing & seal:

17. Remove inner rack seal from housing using tool L-4627.
18. Remove lower pinion bearing retaining ring, then using a suitable drift, tap lower pinion bearing from housing.
19. Using a suitable drift, tap upper pinion bushing and seal from housing.
20. Using a suitable flare wrench, loosen fittings and remove cylinder lines from housing. Also remove line fitting Of-rings.
21. Mark breather tube location on housing for reassembly, then remove breather tube and grommet.