Oil Seals Replacement
Fig. 7 Removing rack seal from gear housing:
Fig. 8 Removing rack seat from rack bushing:
Disassemble
1. Remove tie rod and socket assemblies and input shaft and valve assembly as described previously.
2. Remove yoke plug locknut using tool No. T78P-3504-H, or equivalent, then remove yoke plug using a {3-4} in. socket.
3. Remove yoke spring and yoke bearing from gear housing.
4. Working from righthand side of gear, push rack in until it bottoms.
5. Remove snap ring from right end housing, then carefully pull rack out of housing until rack piston contacts rack bushings. Pull on rack until bushing is withdrawn from housing, then remove rack.
6. To remove rack high pressure oil seal, insert tool No. T78P-3504-J, or equivalent, into gear housing until it bottoms. Using a suitable wrench tighten tool until expander is fully tightened, then attach a suitable slide hammer to tool and remove seal, Fig. 7.
7. Using tool No. T71P-19703-C, or equivalent, remove O-rings from rack piston.
8. Position rack bushing, seal end first into tool No. T78P-3504-L, or equivalent, then place tool and bushing in a vise. With tool No. T78P-3504-J, or equivalent, and a suitable slide hammer, remove seal, Fig. 8.
9. Remove O-rings from bushing with tool No. T71P-19703-C, or equivalent.
Assemble
1. Apply grease to rack high pressure oil seal, position seal on tool No. T78P-3504-K, or equivalent, with lip spring facing tool. Place gear housing in vertical position, then place tool into right side of housing. Tap on tool handle until seal is seated. Use care not to cock handle of tool when installing seal.
2. Mark center tooth of rack so that it will be visible through valve bore.
3. Install rubber O-ring into groove on rack piston.
Fig. 9 Installing plastic O-ring on rack piston:
Fig. 10 Positioning sleeve protector on rack:
4. Position plastic O-ring on tool No. T74P-3504-G, or equivalent, then slide tool and O-ring onto rack until they are adjacent to the rack piston. Slide plastic O-ring off tool and into piston groove over rubber O-ring, Fig. 9.
5. Apply lubricant ESB-M1C119-A, or equivalent, to rack teeth. Also apply a light coating of lubricant opposite rack teeth in yoke bearing contact area.
6. Install protective sleeve T74P-3504-K, or equivalent, over rack gear teeth to prevent damage to integral oil seal in gear housing. Also thread sleeve protector T74P-3504-J, or equivalent, over rack threads, Fig. 10.
7. Lubricate plastic O-ring and protective sleeves with power steering fluid.
8. Position small diameter end of tool No. T78P-3504-M, or equivalent, into righthand side opening of gear housing.
9. Place rack toothed end first, into tool No. T78P-3504-M, or equivalent, then carefully push rack into housing until leading end engages internal oil seal. Position tool No. T78P-3504-M, or equivalent, so that it compresses plastic O-ring. Push rack into housing until protective sleeve protrudes from lefthand side of gear housing. Remove tool No. T78P-3504-M, or equivalent, and long protective sleeve from end of rack. Install tie rod and ball socket assembly on left end of rack to prevent rack teeth from damaging internal oil seal.
10. Install two O-rings on rack bushing.
11. Lubricate outer rack oil seal with gear lube, then using tool No. T74P-3504-F, or equivalent, install oil seal in rack bushing with lip spring facing inside of bushing.
12. Lubricate short protective sleeve on rack end and rack bushing O-rings with gear lube.
13. Start bushing with seal end first onto rack. Position bushing and seal over protective sleeve and into housing bore. Using tool No. T78P-3504-M, or equivalent, apply hand pressure to end plate and rack bushing until bushing is seated in housing bore. If bushing will not seat using hand pressure, tap bushing in using a 1{1-8} inch socket and a plastic mallet. Install snap ring and remove protective sleeve.
14. Install tie rod assemblies as described under ``Tie Rod Ends, Bellows and Ball Joint Sockets.''
15. Install input shaft and valve assembly as described under ``Input Shaft and Valve Assembly.''
16. Fill yoke plug hole with 2 ounces of lubricant. Install yoke, spring, plug and locknut. Adjust yoke bearing preload as described under Adjustments.
17. If the external pressure lines were removed, they must be replaced with new pressure lines. Remove the copper seals from the pressure ports previous to installation of new lines. Torque pump to gear pressure line and return line fittings 10---15 ft. lbs. Torque pressure line fittings at valve and power cylinder to 15 to 20 ft. lbs.
18. Apply lubricant under cuts in tie rod, then install bellows, equalizer tube, clamps, jam nuts and tie rod ends.