Disassembly/Assembly
DisassemblyThe only serviceable component of the input shaft and valve assembly are the four plastic O-rings.
1. Clean exterior of steering gear thoroughly.
2. Mount gear in holding fixture tool No. D87P-3504-B or equivalent.Do not hold gear in vise.
3. Do not remove external pressure lines unless they are leaking.
4. Loosen yoke plug locknut to relieve preload on rack.
5. Remove pinion bearing plug using pinion plug spanner tool No. T83P-3504-AH or equivalent.
Fig. 21 Removing Pinion Bearing Locknut:
Fig. 22 Valve Body Puller Tool:
Fig. 23 Lower Pinion Seal Removal Tool:
6. While holding input shaft, remove and discard pinion bearing locknut, Fig. 21.
7. Pry out input shaft dust seal using an appropriate tool.
8. Remove snap ring, located under dust seal, from housing.
9. Attach valve body puller tool No. T86P-3504-D and valve body puller tool No. T81P-3504-T or equivalent to input shaft, Fig. 22.
10. Turn nut to remove valve. Input shaft seal and bearing will come out with valve body.
11. Remove lower pinion shaft seal using seal removal tool Nos. T86P-3504-F, T86P-3504-J and T50T-100-A or equivalent, Fig. 23.
12. Remove pinion bearing from gear housing using puller tool No. T58L-101-B or equivalent.
13. Remove O-rings by pushing rings to one side, then inserting small pointed tool under each ring, and cutting ring off.
Assembly
Fig. 24 Installing Plastic Valve Rings:
1. Install steering gear pinion bearing in gear housing using lower pinion bearing replacer tool No. T81P-3504-H or equivalent. Seat bearing against shoulder in boar. Support valve housing when seating pinion bearing.
2. Apply Steering gear grease No. C3AZ-19578-A or equivalent to pinion seal and place it on lower pinion seal replacer tool No. T87P-3504-C or equivalent with seal lip toward tool.
3. Install short spacer over input shaft of valve assembly, Fig. 24.Install mandrel part of valve seal installer tool No. T75L-3517-A or equivalent over shaft and spacer. Mandrel will line up with second groove from input shaft.
4. Lubricate mandrel with power steering fluid. Place one valve sleeve over mandrel. Rapidly push ring down with pusher tool. Ring will drop into proper groove.
5. Install long spacer over input shaft. Mandrel will line up with first groove on input shaft. Repeat step 4.
6. Repeat steps 3 through 5 sliding mandrel over the pinion end of valve.
7. After four valve sleeves are installed, apply a light coat of steering gear grease to sleeve and rings.
Fig. 25 Installing Seal Sizing Tool:
Fig. 26 Positioning Rack In Housing:
Fig. 27 Proper Input Shaft Position:
8. Slowly install Teflon seal sizing tool No. T87P-3504-F or equivalent over valve sleeve rings, Fig. 25. Ensure that rings are not being bent over or out of grooves as tube is slid over them.
9. Continue sliding sizing tool over rings until it has passed over rings and comes off other end. Ensure rings turn freely in the grooves.
10. Position rack in housing so four complete tooth spaces protrude from lefthand end of housing, then move rack slightly, as necessary, to center tooth visible in valve bore, Fig. 26.
11. Position Teflon seal sizing tool in valve housing bore.
12. Position D-flat on input shaft at the 3 o'clock position and insert valve assembly into bore. The D-flat surface must be at the 3 o'clock position in the vehicle with the gear on center position. Rotate input shaft slightly, if necessary, to mesh the pinion with the rack teeth.
13. Push valve assembly in by hand until seated properly, then remove sizing tool.
14. Using input shaft torque adjuster tool No. T81P-3504-R or equivalent count total turns, stop to stop. From one stop, back off half the total of turns. D-flat should be ad shown in Fig. 27. If not, repeat steps 11 through 13.
15. Install bearing assembly in valve bore and seat with input shaft and seal installer tool No. T78P-3504-D or equivalent.
16. Install input shaft protector tool No. T81P-3504-P or equivalent over input shaft and install input shaft seal with lip spring toward valve.
17. Remove seal protector and seat seal.
18. Install retaining snap ring in valve bore.
19. Apply a generous amount of grease over top of input shaft pressure seal around input shaft.
20. Install dust seal and seat with seal installer tool No. T78P-3504-D or equivalent.
21. Install nut on pinion end of valve assembly. Holding input shaft tighten nut to specifications. Rack must be in center position when tightening.
22. Install steering gear pinion bearing cap, then tighten to specifications.
23. Set rack preload as outlined under ADJUSTMENT PROCEDURES/RACK YOKE PLUG RELOAD.