Gear Housing and Rack Assembly

DISASSEMBLY
1. Remove tie rod and socket assemblies and input shaft and valve assembly.
2. Remove yoke plug locknut using pinion housing yoke locknut wrench T78P-3504-H, or equivalent, then remove yoke plug using a 3/4 inch 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 Pull on rack until bushing is withdrawn from housing, then remove rack.

Rack Seal From Gear Housing Removal:

6. To remove rack high pressure oil seal, insert rack oil seal remover 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.
7. Using O-ring tool T71P-19703-C, or equivalent, remove O-rings from rack piston.

Rack Seal From Rack Bushing Removal:

8. Position rack bushing, seal end first, into rack bushing holding tool T78P-3504-L, or equivalent, then place tool and bushing in a vise. With rack oil seal remover T78P-3504-J, or equivalent, and a suitable slide hammer, remove seal.
9. Remove O-rings from bushing with O-ring tool T71P-19703-C, or equivalent.

ASSEMBLY
1. Apply grease to rack high pressure oil seal, position seal on tool 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.

Plastic O-Ring On Rack Piston Installation:

4. Position plastic O-ring on Teflon(R) ring replacer 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.
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.

Positioning Sleeve Protector On Rack:

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 rack seal protector sleeve T74P-3504-J, or equivalent, over rack threads.
7. Lubricate plastic O-ring and protective sleeves with power steering fluid.
8. Position small diameter end of Teflon(R) ring sizing tool T78P-3504-M, or equivalent, into righthand side opening of gear housing.
9. Place rack toothed end first, into sizing tool, then carefully push rack into housing until leading end engages internal oil seal. Position sizing tool so that it compresses plastic O-ring. Push rack into housing until protective sleeve protrudes from lefthand side of gear housing. Remove sizing tool 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 outer rack seal replacer 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 Teflon(R) ring sizing tool 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.
15. Install 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.
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.
18. Apply lubricant under cuts in tie rod, then install bellows, equalizer tube, clamps, jam nuts and tie rod ends.