Disassembly/Assembly
DISASSEMBLE1. Hold steering gear over drain pan in an inverted position and cycle input shaft six times to drain remaining fluid from gear.
2. Using suitable mounting pads for support, install gear in bench mounting fixture tool No. T57L-500-B or equivalent.
3. Remove locknut from adjusting screw.
4. Turn input shaft to either stop, then turn it back approximately 1 5/8 turns to center the gear. Input shaft spline indexing flat should be facing downward.
5. Remove two sector shaft cover bolts.
6. Tap lower end of sector shaft with a soft-faced hammer to loosen it, then lift cover and shaft from housing as a unit. Discard O-ring.
7. Turn sector shaft cover counterclockwise off adjuster screw.
8. Remove valve housing attaching bolts. Lift valve housing from gear housing while holding piston to prevent it from rotating off worm shaft. Remove valve housing and lube passage O-rings and discard.
9. Remove valve housing attaching bolts and ID tag, while holding piston separate valve housing from housing, remove and discard O-rings.
Fig. 3 Ball Nut & Valve Housing Disassembled:
Fig. 4 Input Shaft Removal:
10. With piston held, remove ball clamp screws and guide clamp, Fig. 3.
11. With finger over ball guide opening, turn piston so ball guide faces downward over clean container, then allow guide tubes to drop to container.
12. Rotate input shaft from stop to stop, until all balls fall from piston, then remove valve assembly from piston. Ensure all balls have been removed. Worm may no longer be removed from piston.
13. Install valve body to bench mounting fixture tool No. T57L-500-B or equivalent, then loosen valve housing race nut lockscrew. Using adjuster locknut wrench tool No. T66P-3553-B and spacer valve housing tool No. T66P-3553-C or equivalents, remove worm bearing race.
14. Slide input shaft, worm and valve assembly from valve housing, Fig. 4.
VALVE HOUSING, REPLACE
Fig. 5 Valve Housing Disassembled:
1. Using puller attachment tool No. T58L-101-B or equivalent, remove and discard dust seal, Fig. 5.
2. Remove snap ring from valve housing, then turn fixture so valve housing is upside down.
3. Install bearing remover tool No. T65P-3524-A2 and installer tool No. T65P-3524-A3 or equivalents to valve body opposite the oil seal, then gently tap bearing and seal from housing, discard seal. Exercise care when inserting and removing tool to prevent damage to valve bore in housing.
4. Remove oil inlet and outlet tube seats with tool T74P-3504-L, or equivalent, if damaged.
5. Coat tube seats with petroleum jelly and position them in housing. Install and tighten tube nuts to press seats to proper location, using brass tube seat replacer tool No. T74P-3504-M or equivalent.
6. Coat bearing and seal surface in housing with a film of petroleum jelly.
7. Install bearing with metal side that covers rollers facing downward, then using bearing installer tool No. T65P-3524-A or equivalent, seat bearing, ensuring smooth bearing operation.
8. Dip new oil seal in premium power steering fluid or equivalent, then place it in housing with metal side of seal facing outward. Drive seal into housing until outer edge of seal does not quite clear snap ring.
9. Place snap ring in housing, then drive on ring until snap ring seats in its groove to locate seal properly.
10. Apply coating of suitable multipurpose grease between seals.
11. Place dust seal in housing with dished side (rubber side) facing outward. Drive dust seal in place so that it is located behind undercut in input shaft when it is installed.
WORM & VALVE SLEEVES, REPLACE
1. Cut valve sleeve rings from valve sleeve, then position worm end of assembly in soft jawed vice.
2. Using tool kit No. T75L-3517-A1, or equivalent, install four valve sleeve rings. After installing rings ensure they turn freely in grooves.
PISTON & BALL NUT, REPLACE
Fig. 3 Ball Nut & Valve Housing Disassembled:
1. Remove plastic ring and O-ring from piston and ball nut, Fig. 3.
2. Dip a new O-ring in premium power steering fluid or equivalent lube and install on piston and ball nut.
3. Install new Teflon ring on piston and ball nut, being careful not to stretch it any more than necessary.
GEAR HOUSING
Fig. 6 Steering Gear Housing Disassembled:
1. Remove lower end housing snap ring, Fig. 6.
2. Using puller attachment tool No. T58L-101-B or equivalent, remove and discard dust and pressure seals. Bearing is not serviceable and must be replaced as an assembly.
3. Using suitable multi purpose grease, lubricate new pressure, dust seal and sector shaft seal bore.
4. Install dust seal on sector shaft seal replacer tool No. T77L-3576-A or equivalent, with seal raised lip toward tool, then install pressure seal with lip away from tool, pressure seal flat side should be against flat side of dust deal.
5. Install tool to sector shaft bore, then drive tool until seals clear snap ring grooves. Do not bottom seal against bearing or seals will not function properly.
6. Install snap ring in housing groove.
Fig. 7 Assembling Piston On Worm Shaft:
ASSEMBLE
1. Install worm and valve in housing.
2. Install retaining nut in housing, then torque nut using tool No. T66P-3553-B. Because length of tool required to torque nut will affect torque wrench reading, the following formula must be used to determine torque. Torque (using tool T66P-3553-B, or equivalent) equals (length of torque wrench x 72 ft. lbs.)/(length of torque wrench + 5.5 inches).
3. Install race nut screw and tighten to specifications.
4. Place piston on bench with ball guide holes facing up. Insert worm shaft into piston so that first groove is in alignment with hole nearest to center of piston, Fig. 7.
5. Place ball guide into piston. Place balls in guide (27 minimum), turning worm clockwise (viewed from input end of shaft). If all balls have not been fed into guide upon reaching right stop, rotate input shaft in one direction and then in the other while installing balls. After balls have been installed, do not rotate input shaft or piston more than 3 1/2 turns off the right stop to prevent balls from falling out of circuit.
6. Secure guides to ball nut with clamp and tighten to specifications.
7. Apply petroleum jelly to piston seal.
8. Place a new O-ring on valve housing.
9. Slide piston and valve into gear housing, being careful not to damage seal.
10. Align lube passage in valve housing with one in gear housing, place O-ring in gear housing oil passage hole, then identification tag and install but do not tighten attaching bolts at this time.
11. Rotate ball nut so that teeth are in same plane as sector teeth. Tighten valve housing attaching bolts.
12. Position sector shaft cover O-ring in gear housing. Turn input shaft as required to center piston.
13. Apply petroleum jelly to sector shaft journal, then position sector shaft and cover into gear housing. Install air conditioner line mounting bracket, if equipped, and two sector shaft cover bolts, then tighten to specifications.
14. Attach an inch lb. torque wrench to input shaft and adjust mesh load as outlined previously.