Disassembly and Assembly
Fig. 1 Exploded View Of Rack & Pinion Steering Gear:
Fig. 2 Tubing Seat Locations:
Fig. 3 Exploded View Of Valve Body:
DISASSEMBLE
1. Position steering gear in a soft jawed vise.
2. Disconnect valve body to steering gear hydraulic tubes, Fig. 1.
3. Remove steering gear mounting brackets and bushings.
4. Using two screwdrivers and a self tapping screw, remove brass tubing seats from steering gear housing, Fig. 2.
5. Using a suitable cold chisel, remove pinion shaft dust boot.
6. Using a No. 40 Torx bit, remove valve body attaching bolts and valve body.
7. Wrap cloth around valve body, then position valve body in vise.
8. Remove valve body end plug, then remove pivot lever collar, Fig. 3.
9. Using a suitable punch in pivot lever hole, slide spool valve part way out of valve body.
10. Carefully remove spool valve from valve body, then remove spool valve O-ring.
11. Place alignment marks on tie rods, jam nuts and tie rod ends so they can be installed in the same position.
12. Remove tie rod ends and jam nuts from tie rods.
13. Remove tie rod boots from steering gear housing.
14. Using a suitable cold chisel, uncrimp tie rod washer tabs.
15. Position rack in a soft jawed vise, then using a suitable wrench, remove tie rods from rack.
16. Loosen locknut, then remove adjusting plug, spring and yoke from steering gear.
17. Protect outer bulkhead with a cloth, then remove outer bulkhead using a pipe wrench.
18. Remove O-ring from outer bulkhead and discard.
19. Pull pinion shaft assembly out through lower bearing side of steering gear housing.
20. Using a wooden dowel, drive upper pinion bearing out of housing.
Fig. 4 Removing Rack From Steering Gear Housing:
21. Remove rack from steering gear housing in direction indicated in Fig. 4.
22. Using tool No. T87C-3504-A, remove rack inner guide and seal.
INSPECTION
Check rack and pinion teeth for wear and damage. Position rack in V-blocks and check run-out using a suitable dial indicator. Rack run-out should not exceed .012 inch. Check pinion bearing for looseness and wear. If rack, pinion or pinion bearings are found to be unsatisfactory, the rack and pinion must be replaced as a set.
Check steering gear housing for wear and damage. Check tie rod ball units for looseness and smoothness of operation. Check for bent tie rods or tie rod ends. Check tie rod boots for damage. If any components are found to be unsatisfactory, they should be replaced.
Check rack bushing located inside steering gear housing for wear. The bushing and steering gear housing must be replaced as an assembly. Check yoke sliding surface for wear and replace as necessary. Check outer bulkhead bushing for wear and replace as necessary.
Check pivot lever collar for wear and damage and replace as necessary. Also check spool valve for wear and damage and polish with crocus cloth as necessary.
Fig. 5 Installing Spool Valve:
Fig. 6 Applying Grease To Rack:
ASSEMBLE
1. Install replacement O-rings on spool valve. Apply molybdenum disulfide grease to spool valve pivot lever hole. Lubricate remainder of spool valve with automatic transmission fluid.
2. Position spool valve into valve body, Fig. 5.
3. Apply molybdenum disulfide grease to pivot lever hose in valve body and to ends of pivot lever collar and bushing, install pivot lever into valve housing, ensuring spherical ends are properly seated.
4. Install valve body end plug, Fig. 1.
5. Lubricate inner rack guide and seal with automatic transmission fluid, then install guide and seal using tool No. T87C-3504-A or equivalent. Push guide and seal into housing until fully seated.
6. Apply grease to rack teeth, then position rack seal protector D83P-3504-K or equivalent over rack teeth. When applying grease teeth, do not cover rack air hole, Fig. 6.
7. Using tool T81P-3504, install rack piston seal.
8. Lubricate rack piston and housing cylinder bore with automatic transmission fluid, then slide rack into housing until fully seated. Remove rack seal protector from rack teeth.
9. Using tool T81P-3504-Y or equivalent, install replacement bushing into outer bulkhead. Also install replacement sealing ring, O-rings and oil seal on outer bulkhead. Prior to installation, lubricate bushing and seals with automatic transmission fluid.
Fig. 7 Tightening Outer Bulkhead:
Fig. 8 Staking Outer Bulkhead To Housing:
Fig. 9 Positioning Rack & Pinion:
10. Position outer bulkhead to steering gear housing, then wrap bulkhead with a cloth for protection and tighten with a pipe wrench, Fig. 7.
11. Stake outer bulkhead to rack housing using a suitable punch, Fig. 8.
12. Position lower pinion bearing onto pinion shaft, then tighten and stake nut to pinion shaft. Prior to staking, tighten to specifications.
13. Install pinion shaft assembly, with rack and pinion positioned as shown in Fig. 9.
14. Apply grease to upper pinion bearing, then install bearing using tool No. T78P-3504-D.
15. Tighten pinion bearing cover to specifications.
16. Install and tighten housing locknut to specifications.
17. Position valve body and gasket to steering gear housing, then install Torx attaching bolts.
18. Install yoke, spring, adjusting plug and locknut. Tighten adjusting plug to specifications.
19. Adjust preload as outlined under ADJUSTMENT PROCEDURES/RACK YOKE PRELOAD/SUPPORT YOKE.
20. After completing adjustment, tighten adjuster plug locknut to specifications.
21. Position rack in soft jawed vise, then install tie rod and tighten to specifications.
22. Stake tie rod tab washer at two locations.
23. Install tie rod boots over tie rod and steering gear housing, then install lock wires and clamps.
24. Install tie rod ends and jam nuts, aligning marks made during disassembly.
25. Wrap electrical tape around pinion shaft, then apply grease to shaft. Apply grease to pinion shaft seal lips, then install seal using tool T78P-3504-D. After seal has been installed, remove tape from pinion shaft.
26. Install rack support bushings and brackets.
27. Install replacement tubing seats, then connect hydraulic tubing to steering gear and valve body.