Input Shaft & Valve Assembly

Fig. 4 Yoke Plug Locknut Removal & Installation:

Fig. 3 Adjusting Yoke Plug:

Fig. 10 Removing & Installing Pinion Bearing Locknut:

Disassembly

1. Thoroughly clean rack and pinion assembly and mount in a vise, clamping only by the steel tube section between the rack pressure ports.
2. Do not remove the external pressure lines unless damaged or leaking. If the lines are removed the copper seals must be replaced.
3. Using tool No. T81P-3504-G, or equivalent, loosen yoke plug locknut, Fig. 4, remove yoke plug with tool No. T81P-3504-U, or equivalent, Fig. 3, lift out spring and yoke.
4. Remove power steering gear housing cap.
5. Position tool No. T81P-3504-R, or equivalent, on input shaft. While holding input shaft, remove pinion bearing locknut using a suitable 17 mm socket, Fig. 10. Discard locknut.
6. Remove input shaft seal snap ring.

Fig. 10 Removing & Installing Pinion Bearing Locknut:

Fig. 11 Removing Valve, Input Shaft Seal & Bearing:

Fig. 12 Positioning Lower Pinion Shaft Seal Remover:

Fig. 13 Activating Tool Expander:

Fig. 14 Removing Lower Pinion Shaft Seal:

7. Position input shaft and valve body puller tool No. T81P-3504-T, or equivalent, on input shaft, Fig. 11. Using a suitable wrench, turn nut to remove input shaft, valve body, input shaft seal and bearing.
8. Remove the lower pinion shaft seal using protective sleeve tool T78P-3504-E, or equivalent. Insert the tools into the gear housing. Using a plastic mallet, tap the tool lightly to seat it, Fig. 12. Activate the tool expander, Fig. 13.
9. Using a slide hammer tool No. T50T-100-A, or equivalent, remove seal, then tools, Fig. 14.
10. Position a suitable expanding type puller over the gear housing and remove pinion bearing. Remove the pinion bearing only if damaged.
11. If the valve assembly plastic seal rings are to be replaced use a sharp pocket knife to cut them off. Use care not to scratch or nick the valve sleeve.

Assembly

Fig. 15 Pinion Bearing Installation:

Fig. 16 Valve Assembly Sleeve Ring Installation Sequence:

1. Support the valve housing on a clean flat surface. Using tool No. T81P-3504-H, or equivalent, install new pinion bearing, Fig. 15.
2. With the valve housing supported as in step 1, apply grease to a new pinion oil seal. Using a suitable seal installer, position the pinion oil seal on the installer with seal lip towards tool and install in valve housing, seating seal against shoulder.
3. Install four valve sleeve rings, refer to Fig. 16 A-F, (substeps A through F appear within Fig. 16) and the following steps:
a. Lubricate sleeve tool No. T81P-3504-M1, or equivalent, with automatic transmission fluid type F or equivalent, position tool over valve assembly, Fig. 16 (substep A).
b. Place valve sleeve ring over tool, quickly push down on pusher tool No. T81P-3504-M2, or equivalent, sliding the ring down into the fourth groove, Fig. 16 (substep B).
c. Using automatic transmission fluid type F, lubricate inside of sizing tool T81P-3504-M3, or equivalent, slowly work the tool over the installed ring to seat it. Take care not to deform the ring. Repeat this step after each ring is installed, Fig. 16 (substep C).
d. Position spacer tool No. T81P-3504-M4, or equivalent, over input shaft with the thin lip toward the input shaft splines. This aligns the sleeve tool No. T81P-3504-M1, or equivalent, with the third groove, Fig. 16 (substep D), repeat substeps A, B and C.
e. Position the second spacer tool with the lip toward the input shaft splines, Fig. 16 (substep E). Repeat steps A, B and C.
f. Remove the second spacer and turn it over so the thin lip of the second spacer contacts the thin lip of the first spacer, Fig. 16 (substep F). Repeat steps A, B and C.
4. Remove tools from input shaft and valve assembly, carefully inspect sleeve rings to ensure they are seated correctly and turn freely in their grooves.
5. Position rack in rack housing with three rack teeth protruding from left side of housing. Carefully observe rack while looking through valve housing bore and center the visible rack tooth in the valve bore.

Fig. 17 Installing Valve Assembly:

Fig. 18 Installing Input Shaft Bearing:

6. Insert sizing tool No. T81P-3504-M3, or equivalent, into valve housing. Position ``D'' flat on input shaft at the 3 o'clock position and carefully install valve assembly into housing, Fig. 17.
7. Check to ensure that pinion is centered, turn input shaft with a suitable tool and count the number of turns from pinion shaft center to each steering stop. If the number of turns is unequal, pull out the valve assembly and repeat steps 5 and 6. If still unequal, pull the valve assembly out far enough to free the rack and pinion gears and rotate pinion gear 60° (one tooth). Reassemble, retest and repeat procedure if necessary.
8. Using tool No. T81P-3504-R, or equivalent, install input shaft bearing, wide face up in valve bore, Fig. 18.
9. Holding input shaft with a suitable tool install a new locknut on pinion end, tighten locknut to specifications, Fig. 10. This operation must be performed with the rack near center position.
10. Install input shaft seal protector tool No. T81P-3504-P, or equivalent, over input shaft, apply a film of gear lube part No. C3AZ-19578-A or equivalent to the input shaft seal and install seal with lip spring facing valve assembly.
11. Install input shaft seal retaining snap ring.
12. Install power steering gear housing cover, then tighten to specifications.
13. Fill yoke housing with 2 ounces of gear lubricant part No. C3AZ-19578-A or equivalent, install yoke.
14. Install yoke thrust spring and yoke plug. Refer to Steering and Suspension/Steering/Rack and Pinion/Adjustments. Install yoke plug locknut and tighten to specifications while holding yoke plug in position, Fig. 4.
15. If the external pressure lines were removed during disassembly they must be replaced using new copper seals. Crimp copper seals to the lines with pliers using caution not to damage the exterior of the seals. Do not drop the seals into pressure ports as they may misalign.