Disassembly and Assembly

Fig. 15 Exploded View Of Power Steering Gear:

Disassembly
1. Position rack in suitable soft jawed vise.
2. Using suitable tool, remove turn tubes and O-rings, Fig. 15.
3. Loosen tie rod end locknut, then place installation alignment marks on tie rod end and rack end, remove tie rod end.
4. Remove back boots. Do not damage rack boots or rack housing.
5. Unstake claw washers, then using suitable tool, remove rack ends, mark right and left rack ends and remove claw washers.
6. Using suitable tool, remove rack guide spring cap locknut.
7. Using suitable tool, remove rack guide spring cap.
8. Remove rack guide spring, rack guide and seat.
9. Remove rack housing cap.
10. Using suitable tool to hold control valve, remove self locking nut.
11. Remove control valve housing dust cover, place installation alignment marks on valve and rack housing, remove valve housing, valve and rack housing gasket.
12. Tap out control valve and oil seal.
13. Place installation alignment marks on No. 2 bracket and rack housing, then using suitable screwdriver, pry No. 2 bracket clasp apart, remove bushing and bracket.
14. Using suitable tool, turn cylinder end stopper clockwise until wire end comes out, then turn cylinder end stopper counterclockwise and remove wire.
15. Using suitable brass bar, tap out rack with rack bushing and remove O-ring.
16. Using suitable tool and brass bar, drive out oil seal and spacer.
Assembly
1. Coat cylinder side oil seal lip with power steering fluid, then press in cylinder side oil seal and spacer.
2. Install tool No. 09631-33010 or equivalent to rack, scrape burrs from rack teeth end and burnish as required, coat tool with power steering fluid, the install rack to cylinder, remove tool.
3. Install rack bushing and cylinder end stopper pushing in until wire installation hole appears.
4. Install wire end to hole, then using suitable tool, turn cylinder end stopper clockwise until wire end disappears.
5. Install suitable vacuum tool to cylinder housing unions, apply 15.75 inch Hg. vacuum for about 30 seconds, ensure no change in vacuum, if change is indicated, inspect rack housing oil seal installation.
6. Install No. 2 bracket and bushing, aligning matchmarks.
7. Place suitable vinyl tape on control valve, coat Teflon rings with power steering fluid, then install control valve into housing and press in new oil seal.
8. Position new gasket on rack housing, align valve and rack housing matchmarks, install attaching bolts and tighten to specifications, then install dust cover.
9. Using suitable tool, hold control valve, install new self locking nut and tighten to specifications.
10. Apply Loctite 242 or equivalent to two or three rack housing cap threads, then install cap, using suitable center punch, stake housing in two places.
11. Install rack guide seat, rack guide and spring.
12. Apply Loctite 242 or equivalent to two or three spring cap threads, then install cap, tighten to specifications.
13. Return rack guide spring cap 12°, turn control valve shaft right and left one or two times, loosen spring cap until rack guide compression spring is not functioning, then using suitable tool, tighten rack guide spring cap until turning preload of 6.9-12.2 ft. lb. is indicated.
14. Apply Loctite 242 or equivalent to two or three rack guide spring cap locknut threads, then install locknut, tighten to specifications, then recheck preload as outlined in step 13.
15. Install claw washer and rack ends, then using suitable brass bar and hammer, stake claw washer.
16. Ensure tube hole is not clogged, then install rack boots.
17. Install tie rod ends, align matchmarks.
18. Install right and left turn pressure tubes.