Disassembly and Assembly

Fig. 15 Disassembled view of power steering gear. 1984-85 GLC:

Gear Disassembly

1. Drain lubricant from gear, then secure gear in a suitable vise.
2. Remove boot clips and clamps, then the boots, Fig. 15.
3. Secure toothed portion of rack in vise, then raise grooved section of washer with a chisel and remove tie rod ends, washers and damper rings.
4. Remove pressure and return lines from housing.
5. Remove brackets and rubber mountings, then pry oil seal out of top of housing.
6. Remove valve case attaching bolts, then the valve case assembly and gasket.
7. Remove locknut, then the adjust cover, spring and pressure pad.
8. Remove locknut, plug, spacer and ball bearing from bottom of housing.
9. Remove pinion and thrust washer.
10. Countersink the locking area between outer box and cylinder, then remove outer box from rack.
11. Remove rack from gear housing.
12. Tap inner box out of housing using a .59 inch diameter steel rod.

Gear Assembly

1. Apply suitable grease to rack and U-packings and wrap vinyl tape around rack.
2. Slide inner and outer boxes onto rack and start rack into gear housing.
3. Install inner box wire ring in cylinder groove.
4. Apply suitable grease to O-rings and seals, then slide rack into housing. Tighten outer box, then lightly punch the outer box to cylinder to lock into place.
5. Apply suitable lubricant to pinion, then install pinion, thrust washer, ball bearing and spacer. Install thrust washer with gray colored surface toward bearing.
6. Apply suitable grease to inside of plug, then install plug with thrust washer on bearing side. Torque plug to 29-36 ft.lbs., then back plug off 10-20° and secure with locknut.
7. Apply suitable grease to outer portion of pressure pad, then install pad, spring and adjust cover. Torque cover to 29-36 ft.lbs., then back cover off 40-60° and secure with locknut.
8. Install gasket and valve case assembly into housing. Torque case attaching bolts to 12-15 ft.lbs., then tap oil seals into place.
9. Install brackets and rubber mountings, then the pressure and return lines.
10. Check pinion preload using a suitable torque wrench. Preload should measure 4.3-9.5 ft.lbs.
11. Install tie rods, damper rings and washers. Torque tie rods to 43-58 ft.lbs. and stake washers in place.
12. Install boots, boot clamps and clips.