Disassembly and Assembly

Fig. 21 Disassembled view of power steering gear. 1988 929:

Gear Disassembly

1. Drain steering gear lubricant, then secure steering gear and linkage in suitable vise, using tool 49H032320 or equivalent.
2. Remove oil pipes, then the brackets and bushings, Fig. 21.
3. Scribe alignment marks on tie rod ends and tie rods, then remove tie rod ends and the nuts.
4. Uncrimp washers, then, using tool 49H032301 or equivalent, separate tie rod and rack.
5. Remove boot band, then the boot, washer, wire, bracket and the boots.
6. Loosen lock nut and remove adjust cover, then remove plate, spring and rack support.
7. Remove dust cover, valve housing and oil seal.
8. Remove housing cover and nut.
9. Remove upper bearing, oil seals, snap ring and valve sleeve.
10. Remove seal rings and O-rings.
11. Tap pinion to remove pinion shaft assembly from gear housing, then remove seal rings and O-ring.
12. Remove spacer, retaining ring, holder and oil seal from rack, then the seal ring and O-ring.
13. Remove rack from gear housing, then the oil seal and backup ring.
14. Remove lower bearing, then the spacer and center bearing. Use tool 49H032303 or equivalent to remove center bearing, spacer and oil seal.

Assembly

Reverse disassembly procedure to assemble, noting the following:
1. Oil seal and center bearing:
a. Apply lithium base grease to center bearing.
b. Using tool 49H032305 or equivalent, press in center bearing.
c. Apply additional grease, then press in spacer and oil seal.
2. Backup ring and oil seal:
a. Place backup ring on tool 49H032306 or equivalent.
b. Using tool, install backup ring on rack housing.
c. Apply transmission fluid to oil seal.
d. Assemble tools 49H032307 and 49H032308, or equivalents, and place oil seal on tool 49H032308, then remove tool 49H032307.
e. Using tool 49H032308, install oil seal on rack, then remove tool from rack.
3. Rack O-ring and seal ring:
a. Install O-ring and seal ring in seal ring groove of rack.
b. Set tool 49H03309 or equivalent on body, then install rack assembly. Apply transmission fluid to O-ring and be careful not to damage edge of pinion ring groove.
4. Holder:
a. Apply lithium base grease to oil seal.
b. Apply transmission fluid to inner side of holder and the O-ring.
c. Set tool 49H032310 or equivalent on rack, then install holder and remove tool from rack.
d. Place tool 49H032312 or equivalent on rack.
e. Install tool 49H032311 or equivalent onto end of rack and tap lightly until it contacts tool 49H032312. When operation is complete, set oil seal in position inside body.
f. Install spacer.
g. Install retaining link to steering body.
5. Valve:
a. Install O-ring and seal ring in groove of pinion shaft. To compress seal ring, first use loose end (large diameter) of tool 49D032313 or equivalent, then use the narrower end (smaller diameter).
b. Apply transmission to valve and seal rings, then install seal rings.
c. Insert valve into tool 49H032316 or equivalent to compress seal ring and the seal ring of the piston shaft.
d. Install valve assembly to pinion shaft, then install snap ring.
e. Set tool 49H032315 or equivalent on gear housing, then install pinion shaft in gear housing. Be careful not to damage valve or the seal rings.
6. Valve Housing:
a. Apply grease to oil seal and bearing, then use tool 49H032313 or equivalent to install them in gear housing.
b. Set tool 49H032314 or equivalent on pinion shaft.
c. Install valve housing assembly, then the dust cover.
7. Adjust cover:
a. Apply lithium base grease to friction surface of support yoke.
b. Install support yoke, spring and plate into housing, then tighten adjust cover.
8. Housing cover:
a. Apply lithium base grease to lower bearing.
b. Install lower bearing in gear housing.
c. Torque locknut to 25-33 ft.lbs.
9. Tie rod and boot:
a. Install boot, steering damper bracket and new washer on column side.
b. Using tool 49H032301 or equivalent, tighten right side tie rod, then crimp washer. Apply sealant to contacting surface and install bracket with bolt facing away from pinion shaft.
c. Install new washer on tie rod.
d. Torque tie rod to 58-72 ft.lbs., then crimp washer.
e. Apply lithium base grease to inside of boot and install boot.
f. Install tie rod ends, aligning match marks, and torque to 51-58 ft.lbs.
g. Install pipes.
10. Adjusting pinion preload:
a. Repeatedly torque adjust cover to 3.6 ft.lbs. and loosen it three times, then torque to 3.6 ft.lbs. Apply sealant to threads of adjust cover.
b. Using tool 49D032316 or equivalent, loosen adjust cover approximately 25°.
c. Torque locknut to 43-54 ft.lbs.
d. Using tool 490180510B, or equivalent, and spring gauge, measure pinion torque. At neutral position ±90°, gauge reading should be 32-53 ounces. At any other position, gauge reading should be less than 70 ounces. If preload is not as described, repeat procedure.