Power
Fig. 2 Exploded View Of Steering Gear:
Fig. 3 Lower Bearing & Seal Removal:
DISASSEMBLE
1. Place installation alignment marks on tie rod end, jam nut and tie rod.
2. Remove tie rod ends and jam nuts, Fig. 2.
3. Remove each dust boot clamp, then boot wire and discard, then remove boots.
4. Position steering gear in suitable soft jawed vise.
5. Using suitable chisel, uncrimp tie rod tabs, then remove tie rods and discard tabs.
6. Remove pinion shaft cover.
7. Using pinion torque adapter tool No. T90P-3504-KH or equivalent, remove pinion shaft plug.
8. Using pinion seal replacer tool No. T86P-3504-G or equivalent, remove plug bearing and seal, Fig. 3.
9. Remove pinion shaft locknut cover.
10. Using pinion torque adapter T86-3504-K or equivalent, hold pinion shaft, then remove shaft locknut.
11. Using torque gauge tool No. T90P-3504-LH or equivalent, remove yoke adjustment plug locknut, then remove adjusting plug.
12. Remove spring, support yoke, pinion shaft and control valve from gear housing.
13. Using suitable seal remover, remove control valve seal ring.
14. Press bearing from pinion shaft.
15. Using outer box torque adapter tool No. T90P-3504-MH or equivalent, remove steering gear bushing.
16. Remove rack from RH side of housing, then remove rack piston seal ring and discard.
17. Using rack inner seal remover tool No. T87P-3504-A or equivalent, remove inner steering gear seal and discard, then remove guide from housing.
Fig. 4 Pinion Shaft Inner Seal Removal:
18. Using lower pinion seal remover tool No. T86P-3504-F, remover tool No. T86P-3504-J and slide hammer tool No. T50T-100-A or equivalents, Fig. 4, remove pinion shaft inner seal.
19. Using puller attachment T58L-101-B and slide hammer tool No. T50T-100-A or equivalents, remove pinion bearing from housing.
20. Remove steering gear attaching brackets and grommets.
INSPECTION
1. Inspect pinion shaft teeth and bearing for damage.
2. Inspect control valve seal for damage or abnormal wear.
3. Inspect steering rack for cracks or damaged teeth.
4. Inspect steering rack piston seal ring for abnormal wear or damage.
ASSEMBLE
1. Install grommets and mounting brackets.
2. Using pinion bearing installer tool No. T90P-3504-OH and handle tool No. T80T-4000-W or equivalents, install pinion bearing to housing.
3. Using pinion seal installer tool No. T90P-3504-PH and handle T87P-3504-D or equivalents, install pinion shaft inner seal.
4. Lubricate new seal ring using Teflon ring expander tool No. T90P-3504-QH or equivalent, then install to steering rack piston. Ensure seal ring is properly seated. Size seal ring using Teflon seal sizer tool No. T90P-3504-RH.
5. Lubricate inner guide, then slide onto rack.
6. Lubricate inner seal, then using rack seal protector tool No. T87P-3504-H or equivalent, slide seal on rack, then remove protector.
Fig. 5 Steering Rack Replacement:
Fig. 6 Control Valve Seal Replacement:
7. Position Teflon seal sizer tool No. T90P-3504-RH or equivalent, on rack, then slide steering rack onto housing until inner seal is fully seated, Fig. 5.
8. Install steering gear busing using outer box torque adapter tool No. T90P-3504-MH or equivalent.
9. Using suitable vacuum pump, apply 400 mm-Hg to steering gear housing, ensuring vacuum is maintained for 30 seconds, if vacuum is not maintained, replace inner seal.
10. Using Mandrel tool No. T75L-3517-A1, pusher tool No. T75L-3517-A2, Teflon ring sizer tool No. T87P-3504-F and valve seal spacer tool No. T90P-3504-NH or equivalents, install control valve seal ring, Fig. 6.
11. Center rack in housing, then using Teflon ring sizer tool No. T87P-3504-F or equivalent, install pinion shaft and control valve to housing.
12. Using pinion torque adapter tool No. T86P-3504-K or equivalent, hold pinion shaft, then install pinion shaft locknut and tighten to specifications.
13. Install pinion shaft locknut cover, then tighten to specifications.
14. Apply suitable sealant to pinion shaft locknut cover, then using gear bushing adapter tool No. T80L-77209-A or equivalent, install pinion shaft plug seal.
15. Install bearing to pinion shaft plug, then apply suitable grease to plug seal, then using pinion cover torque adapter tool No. T90P-3504-KH or equivalent, install plug.
16. Install pinion shaft cover, support yoke and spring.
17. Apply sealant to yoke adjustment locknut, install adjustment plug and tighten to specifications.
18. Using torque gauge tool No. T90P-3504-H or equivalent, install yoke adjustment locknut, then tighten to specifications.
19. Using pinion torque adapter tool No. T86K-3504-K or equivalent, measure pinion torque, 8.7-10 inch lbs. within a pinion rotation angle of ± 90° from rack center position should be indicated, if not as specified, repeat steps 17 and 18.
20. Install tie rods, then using suitable chisel install tie rod tabs.
21. Install dust boots with wire and clips, then tie rod end jam nut.
22. Install tie rod ends, aligning installation marks, then tighten tie rod end jam nuts to specifications.