Overhaul
Steering GearSpecial Tool(s):
Material:
Disassembly
NOTE: The steering gear input shaft and seals cannot be repaired or installed separately. New gear installation may be necessary.
1. Secure the steering gear in a vise with the indexing flat pointed down. Use protective caps on the vise jaws.
2. Rotate the power steering gear input shaft and control from stop-to-stop and then center the gear.
3. Remove the steering gear sector shaft housing cover bolts.
4. Tap on the lower end of the steering gear sector shaft.
CAUTION: If there is evidence of damage or wear to the steering gear sector shaft, you must install a new steering gear assembly.
5. Remove the steering gear sector shaft.
6. Remove the locking nut from the steering gear sector shaft adjustment screw.
7. Remove the sector shaft housing cover.
^ Hold the steering gear sector shaft.
^ Turn the housing cover counterclockwise.
8. Remove the valve housing bolts and the identification tag.
9. Remove the valve housing and piston assembly.
10. Remove and discard the gasket.
11. Remove the ball bearings.
1 Remove the 2 bolts.
2 Remove the steering gear ball return guide clamp and rotate the piston over a container to collect the 28 steering gear worm balls.
12. Remove the input shaft valve and housing assembly from the piston.
13. Remove and discard the seal.
14. Place the valve housing in the holding fixture special tool and loosen the setscrew.
15. Using the special tool, remove the race nut.
16. Remove the power steering gear input shaft and control from the valve housing.
17. Rotate the valve housing with the holding fixture.
18. Use the puller to remove the power steering gear input shaft seal dust seal.
19. Remove the input shaft snap ring.
20. Rotate the valve housing with the holding fixture, and using the special tool, remove the bearing and power steering gear input shaft seal.
21. Remove the valve housing from the holding fixture.
22. Install the steering gear housing in the holding fixture and remove the steering gear sector shaft dust seal from the sector shaft seal bore.
23. Remove the spacer.
1 Remove the snap ring.
2 Remove the spacer.
24. NOTE: The steering gear sector shaft bearing is not replaceable.
Using the special tool, remove the sector shaft seal.
Assembly
1. Lubricate the sector shaft seal bore.
^ Use multi-purpose grease.
2. Using the special tool, install the sector shaft seal.
^ Lubricate the sector shaft seal, using multi-purpose grease.
3. Install the spacer.
4. Install the snap ring.
5. NOTE: Place the steering gear sector shaft dust seal on the Sector Shaft Seal Replacer so the raised lip is toward the tool.
Using the special tool, install the sector shaft dust seal.
^ Lubricate the steering gear sector shaft dust seal using multi-purpose grease.
6. Remove the steering gear housing from the holding fixture.
7. Position the input shaft bearing in the valve housing and use the special tool and a press to seat the bearing.
8. Using the special tool and a press, seat the power steering gear input shaft seal.
9. Install the input shaft snap ring.
10. Using the special tool, install the power steering gear input shaft seal dust seal.
11. Mount the valve housing to the special tool.
12. Install the power steering gear input shaft and control into the valve housing.
13. Position the power steering gear race nut into the valve housing.
14. Using the special tool, tighten the race nut.
^ Tighten to 99 Nm (73 ft. lbs.)
15. Install the setscrew.
^ Tighten to 2.3 Nm (20 inch lbs.)
16. Remove the valve housing from the holding fixture and position the piston on the worm gear.
17. WARNING: Hold the ball return guides until the cap or clip is reinstalled. Failure to hold the guides will result in a trapped ball or balls, which can cause a vehicle accident. If the ball guides become unseated at any time, remove all the balls and repeat the procedure. Failure to follow these instructions may result in personal injury.
Install the steering gear ball return guide on the piston.
18. WARNING: The correct number of balls are required for correct gear operation. Count the balls and insert each carefully. Failure to follow these instructions may result in personal injury.
WARNING: To make sure the balls are correctly installed, rotate the steering gear input worm gear and rack from one end of travel to the other without allowing the poppet adjuster to contact the valve housing or moving the valve housing pilot face more than 69.1 mm (2-3/4 inches) from the input end of the rack piston. If the steering gear input worm gear and rack cannot be rotated, reinstall the balls. If a steering gear is installed with a steering gear input worm gear and rack that cannot rotate, the steering gear will not function correctly and steering and gear failure can result. Failure to follow these instructions may result in personal injury.
Rotate the piston while holding the steering gear ball return guide and install the 28 ball bearings into the opening in the ball guide.
19. Install the steering gear ball return guide clamp.
1 Position the steering gear ball return guide clamp.
2 Install the bolts.
^ Tighten to 6 Nm (53 inch lbs.)
20. Install a new gasket.
21. Lubricate and install the seal on the piston.
^ Use multi-purpose grease.
22. NOTE: Make sure to align the oil passages in the steering gear housing.
Install the piston assembly into the steering gear housing.
23. Rotate the teeth so they are on the same plane as the steering gear sector shaft.
24. Loosely install the valve housing bolts and the identification tag, if so equipped.
25. Lubricate the O-ring on the sector shaft housing cover.
^ Use multi-purpose grease.
26. Rotate the housing clockwise and install the sector shaft into the sector shaft housing.
27. NOTE: The sector shaft lock nut will be tightened during the steering gear meshload adjustment.
Install the sector shaft lock nut.
28. NOTE: Loosely install the sector shaft housing bolts.
Install the sector shaft and housing assembly.
29. Tighten the bolts.
^ Tighten to 68 Nm (50 ft. lbs.)
30. Tighten the valve housing bolts.
^ Tighten to 50 Nm (37 ft. lbs.)
