Disassembly/Assembly

Prior to disassembly, clean the gear assembly thoroughly in a suitable solvent. Crocus cloth may be used to remove small nicks and burrs provided it is used carefully. When used on the steering gear valve, use extreme care not to round off the sharp edge portions of the two lands located between the valve drilled holes. Remove and discard all O-ring seals, using new ones lubricated with fluid when reassembling.

DISASSEMBLE

1. Drain steering gear by rotating worm shaft from stop to stop.

Fig. 1 Valve body assembly removal:

2. Remove valve body attaching screws, then the valve body. Remove and discard three valve body O-rings.

FIg. 2 Pivot lever removal:

3. Remove pivot lever and pivot lever spring by prying under spherical head of lever with a suitable screwdriver. Use care not to collapse slotted end of pivot lever, as this will destroy spherical head bearing tolerances.
4. Loosen sector shaft adjusting screw locknut, then remove sector shaft cover spanner nut using spanner nut remover No. C-3989 or equivalent.
5. Install No. C-3786 or equivalent, onto threaded end of sector shaft, then slide tool into housing until tool and shaft engage with bearings.
6. Rotate wormshaft to full left turn position to compress power train components, then remove power train attaching nut using spanner nut remover No. C-3989. Remove housing head washer.

Fig. 3 Power train removal:

7. While maintaining power train in a firmly compressed position, pry on piston teeth using a suitable screwdriver and remove complete power train. The cylinder head, center race and spacer assembly and the housing head must be kept in close contact since the reaction rings may become disengaged from grooves in cylinder head and housing. Also, the center spacer may separate from center race and jam in the housing, in turn damaging the spacer and/or housing when removing the power train.

ASSEMBLE

1. With steering gear housing fastened in holding fixture, lubricate power train housing bore with fluid and install power train assembly. Face piston teeth to the right and valve lever hole in center race and spacer in Up position. Ensure cylinder head is bottomed against housing shoulder.
2. With valve lever hole in center bearing race and spacer aligned with valve level hole in gear housing, install valve lever (double bearing end first) into center bearing race and spacer, ensuring valve lever slots are parallel to worm shaft. It may be necessary to gently tap end of valve lever to seat lower pivot point in center race.
3. Install housing head tang washer, indexing with groove in housing, and steering column support nut, and torque nut to 150-200 ft. lbs. Ensure valve lever remains centered in housing hole by rotating worm shaft until piston bottoms in both directions and observe valve lever action. The valve lever must be in center of hole and return to the center position when worm shaft torque is relieved.
4. Install valve lever spring (small end first), position power piston at center of travel and install sector shaft and cover assembly, indexing sector teeth with piston rack teeth. Ensure sector shaft cover O-ring is installed properly.
5. Install and torque cover nut to 110-200 ft. lbs.
6. Install valve body onto housing with valve lever entering hole in valve spool. Ensure O-rings are installed properly, then install and torque valve retaining screws to 7 ft. lbs.