Disassembly and Assembly

Fig. 15 Exploded View Of Power Steering Gear:

Disassembly

1. Place steering assembly in a suitable vise, then remove pressure lines, Fig. 15.
2. Mark position of tie rod and rack end for reference during assembly, then remove tie rod.
3. Remove clips, clamps and rack boots.
4. Unstake claw washers, then using tool 09612-24013, remove both rack ends and washers.
5. Remove rack guide spring cap locknut, then the spring cap, spring, guide and seat.
6. Remove locknut, then the bearing guide nut and control valve housing dust cover.
7. Scribe alignment marks on control valve housing and rack housing, remove retaining bolts, then pull out valve housing and remove O-ring from rack housing.
8. Remove spring seat, spring, control valve and bearing from rack housing.
9. Remove snap ring, then using tool 09612-24013, remove rack together with cylinder end stopper, spacer and oil seal.

Inspection & Repair

1. Check rack for damage, wear or excessive runout. If runout exceeds .012 inch, replace rack assembly.
2. If necessary, replace cylinder housing oil seal and spacer using tool 09631-12020 and suitable drift.
3. If necessary, pry out rack housing oil seal and reinstall new seal using tool mentioned above and suitable drift.
4. If necessary, replace control valve housing oil seal and bearing as follows:
a. Using tools 09630-24013 and 09631-12020, press out oil seal and bearing from housing.
b. Using tools mentioned above, drive seal and new bearing into housing.
5. If necessary, replace rack Teflon ring and O-ring as follows:
a. Pry off O-ring and Teflon ring with suitable tool.
b. Install new Teflon ring onto tool 09630-24013, then insert tool and ring onto rack.
c. Coat Teflon ring with power steering fluid, snug ring down with fingers, then slide tapered end of tool mentioned above over ring to fully seat it into position.
6. If necessary, replace control valve Teflon ring as follows:
a. Pry off Teflon ring with suitable tool.
b. Install new Teflon ring onto tool 09630-24013, then install Teflon ring to control valve and snug down with fingers.
c. Coat ring with power steering fluid, then slide tapered end of tool 09620-24050 over ring to fully seat it into position.
7. If necessary, remove control valve housing union seat with suitable screw extractor. Drive new seat fully into position using an extension bar and hammer.

Assembly

During assembly, coat all moving parts, bearings, and bushings with molybdenum disulfide lithium base grease, and all O-rings and Teflon rings with power steering fluid.
1. Install tool 09631-20101 onto rack assembly, coat tool with steering fluid, then drive rack into housing and remove tool.
2. Install cylinder end stopper, oil seal and spacer as follows:
a. Wind tape around rack end, then coat with steering fluid to prevent damage to oil seal. Install oil seal into rack housing, ensuring seal is not cocked.
b. Install spacer and end stopper, then drive stopper fully inward using suitable tool.
c. Install snap ring.
3. Check rack housing for leakage using suitable vacuum pump and adapters. Housing should hold vacuum for at least 30 seconds.
4. Push control valve into housing, then install O-ring, spring and spring seat.
5. Align marks made during disassembly, then install control valve housing onto rack housing. Coat retaining bolt threads with Loctite 242 or equivalent, then install bolts and tighten specifications.
6. Install lower bearing, coat bearing guide nut threads with Loctite 242 or equivalent, then install guide nut and tighten to specifications.
7. Using suitable torque meter, loosen guide nut until preload is 3.9-5.6 inch lbs.
8. Apply Loctite 242 or equivalent to guide nut locknut, then install locknut and tighten to specifications. Recheck preload and ensure it is as specified in previous step.
9. Adjust total preload as follows:
a. Install rack guide seat, guide and spring. Coat spring cap threads with Loctite 242 or equivalent, then install cap and tighten to specifications.
b. Back off spring cap approximately 15°.
c. Rotate control valve shaft to left and right, then loosen spring cap until rack guide spring no longer functions.
d. Using suitable torque meter, tighten spring cap until preload of 7.8-10.4 inch lbs. is obtained.
10. Apply Loctite 242 or equivalent to spring cap locknut, then install locknut and tighten to specifications. Recheck preload and ensure it is as specified in previous step.
11. Align claws of claw washers with rack grooves, then install rack ends and tighten to specifications, or 61 ft. lbs. for SC 300 & SC 400.
12. Stake claw washers into position, then ensuring that tube hole is not clogged, install rack boots, clamps and clips. Ensure clamp ends face downward and that clip ends face outward.
13. Install tie rod ends, ensuring marks made during disassembly are aligned, then tighten clamps to specifications.
14. Install pressure lines.