Rod/Rack and Cylinder Tube Assembly

Fig. 24 Exploded View Of Power Rack & Pinion Assembly:

1. Remove dust cover from housing, Fig. 24.
2. While holding stub shaft, remove locknut from pinion.
3. With gear centered, mark location of stub shaft notch on housing to aid in proper installation of the pinion and valve assembly.
4. Using a suitable press, press on threaded end of pinion until it is possible to remove the pinion and valve assembly from the housing.
5. Remove stub shaft dust seal, stub shaft seal, stub shaft bearing annulus assembly, then the pinion and valve assembly with spool shaft retaining ring and valve body rings attached.
6. Using wrench, tool No. J 36343, or equivalent, remove cylinder tube assembly from housing. Mark location of fittings on housing before removal.
7. Remove piston rod guide rack from housing and disassemble as follows:
a. Remove hex nut from rod and rack assembly.
b. Remove rack piston with O-ring seal, piston ring and piston rod guide assembly.
c. Remove O-ring seal and piston rod seal from piston rod guide.
8. Remove retaining ring from housing.
9. Remove pinion bearing assembly from housing.
10. Remove pinion shaft seal and upper pinion bushing from housing.
11. Coat all seals with power steering fluid.
12. Install upper pinion bushing into valve bore in housing.
13. Using seal installer tool No. J 29822, or equivalent, seat pinion shaft seal into housing.
14. Using suitable press, install pinion bearing assembly into housing.
15. Install retaining ring in groove in housing, positioning properly.
16. Assemble piston rod seal and O-ring seal to piston rod guide.
17. Assemble O-ring seal and piston ring to rack piston.
18. Slide seal back-up washer, piston rod guide assembly and rack piston onto rod and rack assembly.
19. Install hex nut on rod and rack assembly. Torque to 30 ft. lbs.
20. Slide piston rod guide assembly into housing.
21. Apply one small drop of Loctite 242, or equivalent, in three equally spaced locations around threaded portion of housing. Be sure to use sealant sparingly to ensure ease of removal of cylinder tube assembly if future repairs are necessary.
22. Slide cylinder tube assembly over rack piston ring to housing, then, using torque wrench, or equivalent, torque to 82 ft. lbs. Be sure to align fittings on cylinder tube with mark on housing before tightening to ensure cylinder line installation.
23. Assemble insert and rack guide assembly to rod and rack assembly in housing.
24. Center rack guide assembly in housing window opening.
25. Using protector tool No. J 33057, or equivalent, install pinion and valve assembly, together with new valve body rings, and spool shaft retaining ring into housing. When pinion and valve assembly is fully seated in housing, notch in stub shaft and mark on housing line up and insert and rack guide assembly is centered in window housing.
26. While holding stub shaft, torque locknut to 26 ft. lbs.
27. Install dust cover on housing.
28. Install stub shaft bearing annulus assembly onto stub shaft and slide into housing.
29. Place seal protector tool No. J 29810, or equivalent, onto stub shaft, then slide stub shaft seal and stub shaft dust seal over protector and into housing.
30. Install retaining ring into groove in housing.
31. Coat rack bearing, with O-ring seal attached, adjuster spring and the adjuster plug with lithium base grease and install in housing.
32. With rack centered in window in housing, turn adjuster plug clockwise until it bottoms in housing, then back off 50-70 °. Check pinion preload torque, which should not exceed 16 inch lbs.
32. Install locknut on adjuster plug and torque to 50 ft. lbs. while holding adjuster plug stationary.