Disassembly/Assembly
INPUT SHAFT AND VALVE ASSEMBLYFig. 2 Exploded view of input shaft & valve assembly:
Disassembly
1. Thoroughly clean input shaft valve housing, yoke locknut and plug and the pinion bearing plug.
2. Install steering gear in suitable holding fixture. Do not remove external pressure lines unless they are leaking or damaged. If lines are removed, new teflon seals must be installed.
3. Using suitable tools, loosen yoke plug locknut, then the yoke plug, Fig. 2.
4. Remove pinion bearing plug.
5. Install pinion shaft torque adapter T74P-3504-R or equivalent on input shaft and remove pinion bearing locknut while holding input shaft. Do not allow rack to reach full travel when loosening or tightening locknut.
6. Using suitable tool, Pry input shaft dust seal from housing, being careful not to damage valve housing surfaces.
7. Remove snap ring, located beneath dust seal, from housing.
8. Install suitable puller on input shaft and tighten nut on tool to remove input shaft and valve assembly, together with input shaft seal and bearing, from housing.
9. To remove lower pinion shaft seal, insert seal remover T78P-3504-E2 and spacer collet D82P-3504-E1, or equivalents, until it bottoms, then hold large nut and tighten small nut on tool until expander fully tightens.
10. Install slide hammer in rear of suitable seal remover and pull lower pinion shaft seal from housing.
11. Inspect pinion bearing, removing only if replacement is necessary.
12. Remove O-ring seals only if replacement is necessary.
Assembly
1. If pinion bearing was removed, place lower pinion bearing on installation tool and position bearing and tool in lower housing.
2. Support housing with wooden block and drive pinion bearing into housing until it is seated against shoulder in bore.
3. Coat lower pinion oil seal with suitable lubricant, place seal on installation tool with seal lip facing toward tool, support housing on clean flat surface and drive seal until it is seated against shoulder.
4. If O-ring seals were removed, proceed as follows:
a. Mount pinion end of valve assembly in suitable vise.
b. Lubricate mandrel tool T75L-3517-A1 or equivalent with suitable lubricant and install tool over valve assembly, then slide one valve sleeve O-ring over tool.
c. Slide ring pusher T75L-3517-A2 or equivalent over mandrel and push down rapidly to force O-ring down ramp into fourth groove of valve sleeve.
d. Repeat above step three more times, adding one spacer under mandrel each time.
e. Apply suitable lubricant to sleeve and O-rings.
f. Install one spacer T75L-3517-A3 or equivalent over input shaft, then slowly install sizing tube T75L-3517-A4 or equivalent over sleeve valve end of input shaft onto valve sleeve O-rings, ensuring that O-rings are not being bent over as sizing tube is slid over them.
g. Remove sizing tube and check condition of O-rings, ensuring they turn freely in grooves. If only valve was serviced and rack was not moved while valve was out, skip step 5.
5. If rack was removed and marked with paint, position rack so that paint mark is centered in valve bore. If rack was not removed, position rack in housing so that right end of rack protrudes {9/16} inch from socket to housing.
6. Insert valve body insertion tool T78P-3504-C or equivalent in top of valve housing, lining up D-flat on input shaft 180° from yoke plug hole center and insert valve assembly in bore. The D-flat must point straight to the rear when the gear is installed in the vehicle with the gear in the on-center position. If necessary, rotate input shaft slightly from side to side to mesh pinion to rack teeth. Push valve assembly in by hand until properly seated.
7. Install suitable tool on input shaft and check if pinion is centered by rotating input shaft and counting number of turns from center to each stop. If number of turns is not equal, pull valve assembly out far enough to free pinion teeth, rotate input shaft 60° in direction that requires least turns and reinsert valve assembly. Repeat procedure as necessary until pinion is centered.
8. With rack away from stops, install nut on pinion end of valve assembly, hold input shaft with suitable tool and torque nut to 30---40 ft. lbs.
9. Position input shaft bearing over shaft and in bore, then, using suitable tool, drive bearing into bore until firmly seated.
10. Coat input shaft seal with suitable lubricant.
11. Install input shaft seal with lip toward gear housing.
12. Install input shaft seal over seal protector tool so seal lip faces valve.
13. Drive seal into bore until seated.
14. Install snap ring in valve bore.
15. Coat input shaft with suitable lubricant in dust seal contact area.
16. Install input shift seal tool T85T-3504-CH1 or equivalent over input shaft.
17. Install input shaft dust seal and drive into position with suitable tool.
18. Remove seal tool from seal and input shaft.
19. Install bearing cap, torquing to 50 ft. lbs.
20. Adjust rack yoke plug preload as previously described.
OIL SEAL REPLACEMENT
Fig. 3 Exploded view of gear housing:
Disassembly
1. Remove tie rod and socket assemblies and the input shaft and valve assembly as previously described.
2. Using suitable tool, remove yoke plug locknut, Fig. 3.
3. Remove yoke plug from housing.
4. Remove yoke spring and yoke from gear housing. Remove yoke by gripping on guide post with pair of pliers.
5. Working from right end of gear, push rack into housing far enough to gain access to snap ring.
6. Remove snap ring from right end of gear housing.
7. Using hammer and brass drift, slowly drive rack out of right side of housing together with rack bushing, then remove rack from housing.
8. To remove internal high pressure rack oil seal, insert tool T78P-3504-J or equivalent into housing until it bottoms.
9. Activate expander with wrench until expander fully tightens against oil seal.
10. Insert slide hammer into tool and pull seal from housing. Discard seal. On first attempt, plastic insert may pull out of seal, leaving seal in housing. Repeat procedure until seal is removed.
11. Using suitable tool, remove plastic O-ring and rubber O-ring from rack piston.
12. Remove rack bushing seal by gripping seal in vise and squeezing seal to distort it, then pry out with screwdriver.
Fig. 4 Installing plastic insert in rack seal:
Assembly
1. Mark center tooth (11th tooth) on rack so that mark will be visible in valve bore.
2. Slide ring replacer T74P-3504-G or equivalent on rack until it seats on piston, then install rubber O-ring in rack piston groove.
3. Slide plastic O-ring over tool into piston groove over rubber O-ring.
4. Remove and retain plastic insert from rack seal.
5. Install rack seal protector tool T85L-3503-B or equivalent over rack teeth.
6. Lubricate rack and the tool with suitable lubricant.
7. Install seal so that lip faces toward piston. Push seal all the way against piston. Remove rack seal protector.
8. Install plastic insert into rack seal, Fig. 4.
9. Pack rack teeth with suitable lubricant and apply light coat of lubricant to yoke contact area in back of rack teeth.
10. Apply suitable lubricant to to piston seal and rack seal O. D.
11. Install teflon ring sizing tool T78P-3504-M or equivalent into end of gear housing.
12. Install rack, being careful not to scratch housing piston bore.
13. Carefully push piston through sizing tool, pushing on rack until it bottoms, then remove sizing tool.
14. Seat rack seal with rack by driving end of rack with suitable tool. Do not remove rack.
15. Install left tie rod and ball socket on rack and hand tighten.
16. Thread rack sleeve protector T74P-3504-J or equivalent over threads on right side of rack and coat sleeve with suitable lubricant. Rack must not move too far from center as excessive travel may cause rack teeth to cut left inner oil seal.
17. Apply suitable lubricant to outer rack oil seal and, using suitable tool, install high pressure oil seal in rack bushing.
18. Apply suitable lubricant to short protective sleeve on rack and the seal O. D. on the rack bushing.
19. Start bushing on rack with seal facing inward and pass bushing and seal over protective sleeve and into housing bore. Using tool T78P-3504-M or equivalent, apply hand pressure to rack bushing until bushing seats in gear housing. If rack bushing will not seat with hand pressure, a 1 {1/8} inch, 12 point or larger deep socket and a plastic mallet may be used to tap bushing in place.
20. Install snap ring in right end of gear housing.
21. Install right tie rod assembly. Torque both tie rod sockets simultaneously to 55---65 ft. lbs. by holding one and turning the other.
22. Install coiled pins in sockets by lightly tapping with hammer until seated.
23. Fill yoke plug hole with 2 ounces of suitable lubricant.
24. Install yoke plug in gear housing.
25. Install yoke in gear housing.
26. Install yoke spring in yoke.
27. Start yoke plug and locknut in gear housing.
28. Install input shaft and valve assembly as previously described.
29. Adjust rack yoke plug preload as previously described.
30. Apply suitable lubricant to under-cut in tie rods where bellows clamp to tie rods.
31. Install bellows and breather tube, using new clamps.
32. Install clamps retaining bellows to tie rods.
33. Install jam nuts and tie rod ends on tie rods.