Disassembly and Assembly

Disassembly

1. Remove steering gear as outlined under REMOVAL/INSTALLATION.
2. Clamp steering gear in a suitable vise using special service tool No. 09612-00012 or equivalent.

Fig. 15 Exploded View Of Gear Housing:

3. Remove right and left pressure tubes using power steering hose nut wrench tool No. 09633-00020 or equivalent, Fig. 15.
4. Place alignment marks on right and left tie rod ends then remove tie rod ends.
5. Remove rack boot clip, clamp then the boot.
6. Unstake the claw washer, then using special service tools Nos. 09612-100093 and 09612-24014, or equivalents remove rack ends and claw washers.
7. Remove damper support bracket side boot.
8. Remove damper support bracket using overhaul tools. Bracket locknut has lefthand threads.
9. Remove rack guide spring cap locknut using overhaul tools.
10. Remove rack guide spring, rack guide, and rack guide seat.
11. Remove rack housing cap.
12. Remove self-locking nut using special service tool No. 09616-00010, or equivalent.
13. Remove dust cover.
14. Remove control valve housing as follows:
a. Using special service tool No. 09313-30021 or equivalent, remove two bolts.
b. Pull out valve with valve housing.
c. Remove O-ring from valve housing.
15. Remove control valve.
16. Remove lower bearing and spacer.
17. Remove cylinder end stopper, spacers, oil seal and rack as follows:
a. Using snap ring pliers, remove snap ring.
b. Using a press and special service tool No. 09612-24014 or equivalent, press rack until end stopper slightly touches the press block.
c. Pull out rack with cylinder end stopper, spacer and oil seal.
18. Remove rack housing oil seal and spacer by using oil seal remover tool Nos. 09631-12020 and 09631-20031, or equivalent.

Inspection

1. Check rack for excessive runout, tooth wear and damage. Maximum runout is .012 inch. Replace rack if necessary.
2. Replace rack housing side oil seal and bearing as follows:
a. Using special service tool No. 09612-30012 or equivalent, remove bearing.
b. Using special service tool No. 09612-30012 or equivalent, remove oil seal.
c. Coat lip of new oil seal lip with power steering fluid.
d. Using special service tool No. 09620-30010 or equivalent, install new oil seal.
e. Using a press and special service tool No. 09620-30010 or equivalent, press in new bearing.
3. Replace control valve housing bearing and oil seal as follows:
a. Using a press and special service tools Nos. 09630-24013 and 09631-12020 or equivalents, press out oil seal with bearing.
b. Coat lip of new oil seal with power steering fluid, then using a press and special service tools Nos. 09630-24013 and 09631-12020 or equivalents, press in new seal, then new bearing.
4. Replace steering rack teflon ring and O-ring as follows:
a. Using a screwdriver, remove teflon ring and O-ring. Ensure care is taken not to damage steering rack.
b. Coat new O-ring with power steering fluid, then install.
c. Expand teflon ring and install. Do not over-expand teflon ring.
d. Coat new teflon ring with power steering fluid and snug it down with your fingers.
5. Replace control valve teflon rings as follows:
a. Using a screwdriver, remove teflon rings. Ensure care is taken not to damage control valve.
b. Install new teflon rings to special service tool No. 09631-20070 or equivalent and expand them.
c. Install expanded teflon rings to control valve and contract them with your fingers.
d. Carefully slide tapered end of special service tool No. 09631-20081 or equivalent over teflon rings to seat the rings.
6. Replace hydraulic reaction chamber teflon rings and O-rings as follows:
a. Using a screwdriver, remove teflon rings and O-rings. Ensure care is taken not to damage control valve.
b. Coat O-rings with power steering fluid and install.
c. Expand teflon rings and install. Do not over-expand teflon ring.
d. Coat new teflon ring with power steering fluid and snug it down with your fingers.
e. Carefully slide tapered end of special service tool No. 09631-30021 or equivalent over teflon rings to seat the rings.
7. Replace pressure control valve as follows:
a. Using special service tool No. 09313-30021 or equivalent, remove three bolts.
b. Remove three O-rings from housing, then coat three new O-rings with power steering fluid and install them in housing.
c. Using special service tool No. 09313-30021 or equivalent, install new pressure control valve. Torque bolts to 13 ft. lbs.
8. Using a screw extractor, remove union seats, then using a plastic hammer and sliding handle, lightly tap in new seats.

Assembly

1. Coat sliding components with power steering fluid.
2. Install rack housing oil seal and spacer as follows:
a. Coat lip of new oil seal with power steering fluid.
b. Insert special service tools Nos. 09631-12020 and 09631-32010 or equivalents into oil seal and spacer.
c. Softly tap in spacer and oil seal.
3. Install rack as follows:
a. Install special service tool No. 09631-20102 or equivalent onto steering rack.
b. Coat tool with power steering fluid then insert rack with cover into cylinder. Remove cover tool.
4. Install cylinder end stopper, oil seal and spacers as follows:
a. Wind vinyl tape on steering rack end and apply power steering fluid.
b. Install oil seal by pushing it into the cylinder without tilting.
c. Install two spacers.
d. Using special service tool No. 09612-22011 or equivalent, drive in cylinder end stopper.
e. Using snap ring pliers, install snap ring.

Fig. 13 Connecting Oil Seal Test Tool:

5. Perform air tightness test 1 as follows:
a. Install oil seal test tool No. 09631-22030 or equivalent on unions of cylinder housing, Fig. 13.
b. Apply 15.75 inches of vacuum for about 30 seconds.
c. Ensure there is no change in the vacuum reading.
d. If reading changes, check installation of rack housing oil seals.
e. Remove L joint from seat test tool and install L joint to union of cylinder end side.
f. Apply 15.75 inches of vacuum for about 30 seconds.
g. Ensure there is no chance in the vacuum reading.
h. Repeat procedure for other side of cylinder.
i. If reading changes, check teflon ring and O-ring of rack.
6. Coat new control valve teflon rings with power steering fluid and push control valve into housing. Use care not to damage teflon rings.
7. Coat new control valve housing O-ring with power steering fluid and install it to the housing.
8. Using special service tool No. 09313-30021 or equivalent, torque two bolts to 13 ft. lbs.
9. Install lower bearing and spacer.
10. Install self-locking nut using special service tool No. 09616-00010 or equivalent.
11. Apply special grease to rack housing cap and Loctite Three Bond Sealant No. 242 to 2 or 3 threads then torque housing cap to 51 ft. lbs. and stake into place.
12. Install rack guide seat, rack guide and rack guide spring.
13. Adjust total preload as follows:
a. Apply Loctite Three Bond Sealant No. 242 to 2 or 3 threads then using special service tool No. 09612-24014 or equivalent torque spring cap to 18 ft. lbs.

Fig. 14 Adjusting Total Preload:

b. Using special service tool No. 09612-24014 or equivalent, return rack guide spring cap 12-15°, Fig. 14.
c. Turn control valve shaft right and left one or two times.
d. Loosen spring cap until rack guide compression spring is not functioning.
e. Using a torque wrench and special service tools Nos. 09612-24014 and 09616-00010 or equivalents, tighten rack guide spring cap until the preload of 7.8-10.4 inch lbs. is reached.
14. Install rack guide spring cap locknut as follows:
a. Apply sealant to 2 or 3 threads of rack guide spring cap locknut.
b. Using special service tools Nos. 09612-24014 and 09617-24020, install and torque locknut to 41 ft. lbs.
c. Recheck total preload.
15. Install dust cover.
16. Install damper support bracket to rack end and tighten locknut by hand.
17. Install damper support bracket side boot to rack housing end.
18. Install claw washers and rack end as follows:
a. Install a new claw washer.
b. Using special service tools Nos. 09612-24014 and 09617-14010 and torque wrench 11.81 inches long, install and torque rack end to 65 ft. lbs.
19. Adjust damper installation surface to the damper support bracket at right angle to the under flat face of valve housing side mounting positions as follows:

Fig. 16 Adjusting Damper Support Bracket:

a. Place gear housing onto two prisms on the stool and then set mounted face of gear housing parallel to the stool, Fig. 16.
b. Using a square, check and adjust damper support bracket at a right angle and lightly tighten the locknut. Place alignment marks on damper support bracket and rack end.
c. Using overhaul tools, tighten locknut so that marks made are aligned.
d. Torque locknut to specification using special service tools Nos. 09612-10093 and 09617-14010 or equivalents and 11.81 inch long torque wrench.
e. Recheck damper support angle.
20. Using a brass bar and hammer, stake claw washers.
21. Install rack boots, clamps and clips. Ensure tube hole is not clogged with grease.
22. Install tie rod ends aligning marks made during disassembly. Torque tie rod locknuts to 41 ft. lbs.
23. Install right and left turn pressure tubes.