Disassembly/Assembly

On 1989-92 models, gear is not repairable. If a problem is indicated, unit must be replaced.
1. Mark location of tie rod end on tie rod, loosen jam nut and remove tie rod end.

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

2. Remove jam nuts and bellow clamps.
3. Mark breather tube location on bellows and remove from steering gear.

Fig. 2 Removing inner tie rod from rack:

4. using a wrench to prevent rack from rotating, position a wrench on inner tie rod pivot housing flats. Turn housing counterclockwise until tie rod assembly separates from rack.

Fig. 3 Exploded view of rack bearing:

5. Loosen adjuster plug locknut then, remove adjuster plug, spring and rack bearing.

Fig. 4 Removing rack bulkhead retaining wire:

6. Using a punch, rotate the right side rack bulkhead retaining wire clockwise to expose end of retaining wire. Pull retaining wire out of cylinder slot.
7. Turn stub shaft, moving rack to the right forcing the bulkhead out of the housing. Use drain pan to catch excess fluid. Remove rack.
8. Remove input shaft retaining ring, followed by pinion plug.

Fig. 5 Removing pinion locknut from pinion shaft:

9. While holding stub shaft in place with holding fixture No. SP-3616, remove pinion locknut from pinion shaft. If stub shaft is not held in place while removing locknut, damage to the pinion teeth may result.

Fig. 6 Removing valve & pinion assembly:

10. If only stub shaft seals are to be replaced, position tool No. L-4594-1-2-3 over stub shaft and pull valve and pinion assembly out of valve housing until flush with ball bearing assembly. Complete removal of valve and pinion assembly is not necessary to replace stub shaft seals.
11. 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 tool No. L-4594-1-2-3 pull valve and pinion assembly out of valve housing. If necessary, remove valve body seal rings.

Fig. 7 Removing pinion shaft lower seal:

12. Remove pinion shaft lower seal using seal remover No. C4694.
13. Remove pinion bearing using a drift or punch, gently tap on bearing until bearing is removed.

Fig. 8 Removing inner rack oil seal:

14. Remove inner rack seal from rack housing and dispose using tool No. C-4665.
15. Remove and dispose of rack piston ring, inner rack seal, bulkhead seal and bulkhead O-ring.
16. Mark breather tube to housing location and remove tube.