Rack and Pinion

Fig. 1 Disassembled view of TRW power rack & pinion steering gear. 1982---87 Chrysler Corp. front wheel drive exc. Omni, Horizon, 1983---87 Charger & Turismo:

Fig. 2 Removing roll pin from inner tie rod pivot housing:

Fig. 3 Removing inner tie rod from rack:

Fig. 4 Rack bearing, disassembled:

DISASSEMBLE
1. Mark location of tie rod end on tie rod, loosen jam nut and remove tie rod end.
2. Remove jam nuts and bellow clamps.
3. Mark breather tube location on bellows and remove from steering gear.
4. Remove roll pin from inner tie rod pivot housing using an easy-out.
5. Using a wrench to prevent rack from rotating, position a wrench on inner tie rod pivot housing flats. Turn housing counterclockwise until tie rod assembly separates from rack.
6. Loosen adjuster plug locknut then, remove adjuster plug, spring and rack bearing.

Fig. 5 Removing rack bulkhead retaining wire:

Fig. 6 Removing pinion locknut from pinion shaft:

Fig. 7 Removing valve and pinion assembly:

Fig. 8 Removing pinion shaft lower seal:

7. Using a punch, rotate the right side rack bulkhead retaining wire clockwise to expose end of retaining wire. Pull retaining wire out of cylinder slot.
8. Turn stub shaft, moving rack to the right forcing the bulkhead out of the housing. Use drain pan to catch excess fluid. Remove rack.
9. Remove input shaft retaining ring, followed by pinion plug.
10. While holding stub shaft in place with tool No. SP 3616, remove pinion locknut from pinion shaft. If stub shaft is not held in place while removing locknut, damage to the pinion teeth may result.
11. If only stub shaft seals are to be replaced, position tool No. L-4594-1-2-3 over stub shaft and pull valve and pinion assembly out of valve housing until flush with ball bearing assembly. Complete removal of valve and pinion assembly is not necessary to replace stub shaft seals.
12. To remove valve and pinion assembly, rotate stub shaft until rack is centered in housing, with pinion fully engaged. Mark position of stub shaft flat on housing for reassembly. Using tool No. L-4594-1-2-3 pull valve and pinion assembly out of valve housing. If necessary, remove valve body seal rings.
13. Remove pinion shaft lower seal using tool No. C4694.
14. Remove pinion bearing using a drift or punch, gently tap on bearing until bearing is removed. Do not attempt to remove upper pinion bushing.

Fig. 9 Removing inner rack oil seal:

15. Remove inner rack seal from rack housing and dispose using tool No. C-4665.
16. Remove and dispose of rack piston ring, inner rack seal, bulkhead seal and bulkhead O ring.
17. Mark breather tube to housing location and remove tube.

Fig. 10 Bulkhead oil seal installation:

Fig. 11 Installing bulkhead assembly into rack tube:

Fig. 12 Pinion shaft seal installation:

ASSEMBLE
1. Align breather tube with previously made marks on housing, then install grommet so tabs lock.
2. Install new piston ring on rack, position seal protector No. C-4666 over rack teeth and slide seal with lip facing piston onto rack.
3. Remove seal protector and bottom the seal on rack piston, slide plastic retaining ring on rack onto seal. Slide rack, seal and piston ring into housing, using caution not to rip or deform ring or seal. Tap rack with a rubber hammer to seat seal.
4. Coat all seals with automatic transmission fluid then, assemble new O-ring onto bulkhead followed by new oil seal using tool No. C-4669.
5. Lubricate and install seal protector tool No. C-4670 over rack threads, slide bulkhead assembly and end lock ring over seal protector, O-ring end first and insert in rack tube, using caution not to rip or distort the O-ring.
6. Using tool No. C-4675, seat bulkhead in the rack tube. Install retaining wire by rotating bulkhead assembly counterclockwise. Remove protective tool.
7. Install pinion shaft lower seal using tool No. C-4664. Then using a suitable socket, press in on race of bearing, using caution not to cock bearing.
8. Install seal rings on valve body, if removed.
9. Center rack in housing, then install pinion shaft and valve assembly so that flat on stub shaft will be aligned with mark on housing when assembly is fully seated.

Fig. 13 Stub shaft seal installation:

Fig. 14 Torquing inner tie rod pivot:

10. Install stub shaft bearing then, position seal protector tool No. C-4668 slide shaft seal over protector into valve housing. Seat seal with tool No. C-4667 and install retaining snap ring.
11. Install rack bearing, spring and adjuster plug. Turn adjuster plug until it bottoms, then back plug off 40 to 60 degrees. Install locknut and torque to 50 ft. lbs. while holding adjuster plug in position.
12. Install tie rod assembly on rack. While holding rack in position with a wrench torque inner tie rod pivot housing to 60 ft. lbs.. If rack is not held in position while tightening tie rod housing, damage to the pinion teeth will result.
13. Install roll pin.
14. Lubricate inner surfaces of bellows with silicone or other suitable lubricant. Align bellows marks made previously with breather tube and install bellows with boot seal over housing lip with hole in boot aligned with breather tube. Secure inner clamp.
15. Position bellows outer clamp and jam nut on tie rod. Install tie rod end in the position as removed. Torque jam nut to 50 ft. lbs., then install outer bellows clamp. Ensure bellows is not twisted.