Disassembly and Assembly

DISASSEMBLY

Fig. 3 Disassembled view of manual steering gear. 1984-85 GLC:

1. Drain lubricant from the gear housing by removing filler plug.
2. Hold the steering gear in a vise.
3. Remove mounting bracket and rubber from housing, Fig. 3.
4. Remove tie rod end and boot. Mark the threaded portion of tie rod for reference when reassembling.

Fig. 4 Tie rod removal & installation:

5. Remove tie rod and washer using suitable wrench, Fig. 4, then the side cover, O-ring, nut, screw, spring, seat and rack support.
6. Remove oil seal using small screw driver. Use caution not to damage oil seal portion of housing.
7. Remove stopper ring, then the snap ring using suitable pliers.
8. Remove pinion and bearing assembly. To facilitate removal strike housing lightly with soft mallet while pulling the pinion and bearing assembly out with a pair of pliers.
9. Remove rack, then gear housing.




ASSEMBLY




1. Before assembly the following parts should be coated or packed with lithium base grease or equivalent:
a. Ball and roller bearing on pinion.
b. Lip of oil seal.
c. Inside of gear housing.
d. Sliding surface of rack support, rack bushing and rack.
e. Rack pinion teeth and ball joint of tie rod end.

Fig. 3 Disassembled view of manual steering gear. 1984-85 GLC:

2. Install rack to gear housing, Fig. 3.
3. Install pinion and bearing assembly. If fit between housing and bearing is too tight, adjust by tapping the outer ring of the bearing lightly with a soft mallet until rack and pinion mesh properly.
4. Install snap ring in housing. Tapered side should face out.
5. Install stopper ring with projection portion being placed in the gap of snap ring, Fig. 3.
6. Install new oil seal flush with end surface of housing.
7. Install adjusting screw until tension is felt, then back off 15°.
8. Install rubber mounting brackets.

Fig. 4 Tie rod removal & installation:

9. Install tagged washer, then rack and tie rod. Torque tie rod joints to 43-58 ft.lbs., Fig. 4. Stake washer to conform with groove in rack.
10. Install rubber boot, then boot bands.

Fig. 12 Install tie rod end. 1984-85 GLC manual steering gear:

11. Install tie rod end, Fig. 12.

Fig. 13 Measuring pinion preload w/manual steering gear:

12. Measure pinion preload using suitable scale. Preload should be 5-10 in. lbs. Scale should read 1.3-2.6 lbs., Fig. 13.
13. Install mounting bracket with notch facing down.