Disassembly/Assembly

Fig. 2 Steering Rack Assembly:

Fig. 3 Removing Roll Pin:

DISASSEMBLE

1. Mount steering gear in holding fixture tool No. T57L-500-B.
2. Remove screw and nut from clamp, then the clamp from steering housing.
3. Note position of hydraulic lines for reference during assembly, then remove screw and nut from routing clamp and spread clamp, Fig. 2.
4. Remove two hydraulic lines and routing clamp from steering gear housing.
5. Remove screw and nut from fitting protector, then spread protector and remove, Fig. 2.
6. Remove two remaining hydraulic lines.
7. Using roll pin remover tool No. T78P-3504-N, remove roll pin, Fig. 3.
8. Using a 30mm crowfoot wrench, remove tie rod assembly from rack.
9. Using torque gauge tool No. T88C-3504-AH and yoke locknut wrench tool No. T88C-3504-KH, remove adjuster cover, locknut, spring and pressure pad.
10. Drill out the staked area, then remove the housing cover.
11. Remove snap ring from upper pinion bearing.
12. Using tool No. T88C-3504-BH, hold pinion and remove pinion locknut.
13. Using puller bridge tool No. T86P-3504-D, puller tool No. T78P-3504-B and spacer tool No. T78P-3733-A2, remove pinion and upper bearing from steering gear housing.
14. Remove lower bearing from steering housing.

Fig. 4 Drilling Out Staked Area:

Fig. 5 Removing Rack From Housing:

15. On 1989 models, drill out staked area of rack bushing, Fig. 4.
16. On all models, using adapter tool No. T88C-3504-CH, remove rack bushing assembly.
17. Using slide hammer tool No. D79P-100-A and adapter tool No. T88C-3504-OH, remove the rack from the pinion side of the steering housing, Fig. 5.
18. Using seal remover tool No. T78P-3504-J and slide hammer tool No. D79P-100-A, remove inner rack seal and washer from the tube side of the steering housing.

ASSEMBLY

1. Using seal installer tool No. T88C-3504-DH, install inner rack seal and washer.
2. Using seal installer tool No. T88C-3504-EH, Install teflon seal ring and O-ring onto rack.
3. Install protective sleeve tool No. T85L-3504-B onto the rack, then position ring sizer tool No. T88C-3504-FH on steering housing and install rack into steering housing. Leave protective sleeve in place.
4. With protective sleeve still in place, slide outer box seal into steering housing.
5. Using outer box torque adapter tool No. T88C-3504-CH, install outer box assembly. Tighten outer box assembly to specifications, then stake box assembly in place.
6. Using installer tool No. T88C-3504-HH, install intermediate bearing.
7. Using installer tool T87M-3504-E, install lower pinion bearing.
8. Using seal installer tool No. T88C-3504-MH, install inner pinion seal.

Fig. 6 Installing Seals & Pinion Into Housing:

Fig. 7 Installing Upper Seal:

9. Using seal installation set No. T81P-3504-M, install three teflon seals onto the pinion, Fig. 6.
10. Using set No. T81P-3504-M, install pinion into steering housing.
11. Install upper pinion bearing.
12. Install input shaft seal protector tool No. T81P-3504-P, then install upper pinion seal into steering housing.
13. Remove screw from torque adapter tool No. T88C-3504-BH, then use tool to seat upper seal, Fig. 7.
14. Install pinion snap ring. Ensure snap ring is fully seated in groove.
15. Using tool No. T88C-3504-BH to hold pinion, install pinion locknut and tighten to specifications.
16. Apply suitable thread sealer to housing cover, then install housing cover and tighten to specifications.
17. Using a suitable center punch, stake housing cover in place.
18. Install pressure pad, spring and adjust cover.
19. Using yoke torque gauge tool No. T88C-3504-AH, torque adjust cover to 7.2 ft. lbs., then loosen adjust cover and torque to 3.6 ft. lbs., loosen adjust cover 45°.
20. Using pinion torque adapter tool No. T88C-3504-BH and a suitable inch lb. torque wrench, measure pinion torque. Pinion torque should measure 88.5-123.9 inch lbs., if torque is not within specifications repeat step 19 as necessary.
21. Install adjust cover locknut.
22. Using yoke locknut wrench tool No. T88C-3504-KH, tighten locknut to specifications.
23. Using a 30mm crowfoot wrench, install tie rod assembly into steering rack and tighten to specifications.
24. Install roll pin.
25. Install two hydraulic lines and routing clamp, then install clamp screw and tighten securely.
26. Install two remaining hydraulic lines, fitting protector and remaining clamp on steering housing.