I -Pinion Stub Shaft Seals

A. Disconnect the negative battery terminal.

B. On models without the steering shaft seals (boot) covering the pinion shaft and lower coupling assembly, raise the vehicle on hoist and remove the lower coupling to pinion shaft roll pin. Use a backup to protect universal joint while driving roll pin.

On models with the steering shaft seal (boot) proceed to Step D.

FIGURE 1 - STUB SHAFT SEALS (SAGINAW):

FIGURE 2 - STUB SHAFT SEALS (TRW):

C. Remove pinion dust cover and lock nut (Saginaw) (Figure 1). Remove bearing cap and lock nut (TRW) (Figure 2).

NOTE: IT MAY BE NECESSARY ON THE TRW ASSEMBLY TO LOOSEN THE RACK ASSEMBLY MOUNTING BOLTS AS REQUIRED TO ROTATE RACK ASSEMBLY IN ORDER TO GAIN ACCESS TO THE BEARING CAP AND LOCK NUT.

When removing the lock nut have another person hold the steering wheel or lock steering wheel with ignition key to prevent damage to the pinion in teeth.
D. Remove the steering column and toe plate using the procedures in the appropriate service manual.

E. Remove the steering shaft boot covering the pinion shaft and lower coupling on models so equipped and then raise vehicle and remove the lower coupling-topinion shaft roll pin. Use a backup to protect universal joint while driving roll pin. Lower vehicle.

F. Remove pressure and return lines at pinion housing and allow to drain into proper container.

NOTE: THIS MUST BE DONE TO PREVENT P/S FLUID FROM PUMP AND RESERVOIR TO DRAIN INTO THE MECHANICAL DRIVE AREA OF THE GEAR SET.

G. Remove pinion stub shaft retaining ring.

FIGURE 3 - REMOVE VALVE & PINION ASSEMBLY (TRW & SAGINAW):

H. Using Tool L-4594-1-2-3, pull valve and pinion (stub shaft) assembly (Figure 3) until the bearing assembly is flush with the pinion housing. Then remove tools. Complete removal of valve and pinion assembly is not necessary.

NOTE: TOOL ADAPTER L4594-7 IS REQUIRED FOR STUB SHAFT REMOVAL ON 1983 SAGINAW ASSEMBLY.

FIGURE 4 - INSPECT STUB SHAFT SEALING SURFACES:

I. Remove upper seals and inspect stub shaft for corrosion, nicks, etc. (Figure 4). If corroded or nicked, polish the sealing surface with crocus cloth. Soak the crocus cloth with power steering fluid before using to prevent contaminants from entering valve assembly area. After using crocus cloth, clean out area. In the event the sealing surface is pitted or nicked excessively, replace the valve and pinion assembly.

FIGURE 1 - STUB SHAFT SEALS (SAGINAW):

FIGURE 2 - STUB SHAFT SEALS (TRW):

J. Lubricate the new seals with power steering fluid and install as shown in Figure 1 or Figure 2.

FIGURE 5 - STUB SHAFT SEAL PROTECTOR & SEALS (SAGINAW):

FIGURE 7 - STUB SHAFT SEAL INSTALLER (TRW & SAGINAW):

K. Saginaw Assembly - install stub shaft seal using Tool L-4595 (Figure 7) and seal protector Tool L-4596 (Figure 5).

FIGURE 6 - STUB SHAFT SEAL PROTECTOR & SEAL (TRW):

FIGURE 7 - STUB SHAFT SEAL INSTALLER (TRW & SAGINAW):

TRW Assembly - install shaft seal using Tool C-4667 (Figure 7) and seal protector C-4668 (Figure 6).

FIGURE 8 - STUB SHAFT HOLDING TOOL (TRW & SAGINAW):

FIGURE 1 - STUB SHAFT SEALS (SAGINAW):

FIGURE 2 - STUB SHAFT SEALS (TRW):

L. Hold stub shaft with Tool SP3616 (Figure 8) and torque lock nut as shown in Figure 1 or Figure 2.

M. Install pinion dust cover or bearing cap as shown in Figure 1 or Figure 2.

FIGURE 15:

N. Lubricate shaft and seal area (externally with Mopar Multi-Purpose Lube, PN 2932524, or equivalent to prevent corrosion on shaft (Figure 15).

O. Install steering column and related parts, reversing the removal procedures.

P. Fill and operate system to verify that oil leak is corrected.