Disassembly/Assembly

Disassembly

Fig. 19 Removing Rack Bushing Lock Ring:

Fig. 20 Positioning Internal Rack Seal Removal Tool:

Fig. 21 Removing Internal Rack Seal:

1. Remove tie rods and sockets from both ends of rack, also remove input shaft, valve assembly and rack yoke as described previously.
2. Working from the right side of gear, push in rack until it bottoms. Position rack bushing lock ring tool No. T77P-3504-A, or equivalent, over exposed end of rack and engage socket drive tabs in end plate slots, rotate tool clockwise until the end of the retainer wire is visible in the tube slot, turn tool counterclockwise and using an ice pick or similar tool, start the retainer wire out of the slot and remove, Fig. 19.
3. Pull the rack, end plate, rack bushing and rack piston out the right side of housing. If rack, end plate, rack bushing and rack bushing assembly are difficult to remove, install tie rod hand tight on rack assembly, then install slide hammer weight over tie rod. Install a nut on tie rod to slide weight against, and use the weight and tie rod assembly as a slide hammer to remove rack assembly.
4. Insert internal rack seal remover tool No. T81P-3504-B, or equivalent, into housing bore, tap tool with plastic mallet until it bottoms, Fig. 20. Using a suitable wrench, tighten tool until fully expanded. Attach slide hammer and remove seal and nylon back-up ring, Fig. 21.
5. Cut off rack piston seal ring and remove back-up O-ring with a small pointed tool.

Fig. 22 Removing Oil Seal From Rack Bushing:

Fig. 23 Rack Bushing O-ring Removal:

6. Insert rack bushing in holding tool T81P-3504-D, or equivalent, seal end first. Place tool and bushing in a vise, using tool T81P-3504-A, or equivalent, and a suitable slide hammer remove seal, Fig. 22.
7. Remove rack bushing O-ring by pushing it to one side with fingertips, then roll the O-ring over and remove, Fig. 23.

Assembly

Fig. 24 Rack Bushing Seal Installation:

Fig. 25 Rack Piston, Seal & O-ring Installation:

Fig. 26 Protective Sleeve Installed On Rack:

1. Using rack oil seal replacer tool No. T81P-3504-C, or equivalent, apply power steering fluid to inner rack seal and position seal on tool, seal lip facing tool, Fig. 24. Insert sizing tool T81P-3504-K, or equivalent, in end of rack tube, position seal replacer in sizing tool and carefully push in by hand until bottomed, tap the tool with a plastic hammer to seat the seal, leaving sizing tool installed in rack.
2. Position rack piston seal installer tool No. T81P-3504-L, or equivalent, on rack as shown in Fig. 25, slide rubber O-ring over the tool into piston groove then slide plastic seal ring over tool into piston groove on top of the O-ring.
3. Apply fluid grease C3AZ-19578-A, or equivalent to rack teeth and position long protective sleeve tool No. T81P-3504-J, or equivalent, over the rack gear teeth, Fig. 26.
4. Lubricate piston seal ring and protective sleeve tool with power steering fluid.
5. Position rack in rack sizing tool, carefully push rack into the housing and through rack internal oil seal. Ensure the sizing tool is properly positioned to compress and guide the plastic seal ring into housing bore. Push rack in until the protective sleeve protrudes from left side of gear, remove tools and install lefthand tie rod assembly hand tight.

Fig. 27 Outer Rack Oil Seal Installation:

Fig. 28 Outer Rack Oil Seal & Bushing, Disassembled:

Fig. 29 Nylon Ring Installation:

Fig. 30 Installation Sequence, Rack Bushing, Seal, Nylon Ring & End Plate:

6. Apply gear lube to outer rack oil seal, install oil seal in rack bushing with outer rack oil seal replacer, Fig. 27. Lip spring must face the inside of the bushing, Fig. 28. Install nylon ring in oil seal, Fig. 29.
7. Install outer rack bushing O-ring.
8. Position short protective sleeve tool No. T81P-3504-N, or equivalent, over right side tie ball socket threads, apply automatic transmission fluid to protective sleeve tool and rack bushing O-ring.
9. Position rack bushing with seal and nylon ring facing out on protective sleeve, Fig. 30. Slide the rack bushing over the sleeve into housing bore, place end plate against the rack bushing with drive slots facing out. Remove protective sleeve.

Fig. 31 Installing Rack Bushing Lock Ring:

10. Using lock ring wrench tool No. T77P-3504-A, or equivalent, with drive tabs engaged in the end plate slots, push in end plate until end plate retainer wire groove is visible through the rack cylinder slot. Rotate end plate to line up the retainer wire hole with the cylinder slot, insert bent end of the retainer wire in the wire hole and rotate end plate clockwise until the retainer wire is fully engaged. Turn an additional 180 degrees, Fig. 31.
11. Install tie rod ball sockets as described previously.
12. Install input shaft and valve assembly as described previously.
13. Install yoke bearing, spring, plug and locknut. Prior to torquing locknut, adjust yoke bearing preload as described under ADJUSTMENT PROCEDURES/STEERING GEAR/POWER/RACK PRELOAD
14. Install bellows and tie rod ends.