Manual

Fig. 1 Exploded View Of Manual Rack & Pinion:

Fig. 2 Tie Rod Removal:

Fig. 3 Pinion & Bearing Removal:

Fig. 4 Spacer & Support Yoke Removal:

Disassemble

1. Place alignment marks on tie rod and tie rod end, then remove end.
2. Remove tie rod boot small clips Fig. 1, then remove boot wire at steering gear housing.
3. Slide boot off tie rods.
4. Using suitable hammer and cold chisel, Fig. 2, straighten tie rod to rack tabs.
5. Unscrew tie rod from rack, then remove rods and washers.
6. Remove rack mount brackets and bushings as required.
7. Remove pinion protector, then using suitable screwdriver or seal remover, remove pinion oil seal from shaft. Do not score pinion shaft.
8. Remove pinion oil seal spacer, then pinion bearing snap ring.
9. Using bridge tool No. T90P-3504-GH and pulling screw tool No. T78P-3504-B or equivalents, Fig. 3, remove pinion and bearing assembly from housing.
10. Remove locknut, adjusting bolt, yoke plug and spring.
11. Remove spacer and yoke support, Fig. 4.
12. Pull rack out left side of housing to remove. If rack is remove through rack bushing at right side of housing, bushing damage may result.
13. At steering gear housing, depress bushing locking tabs.
14. Remove rack support bushing from right side of steering gear.
15. Lower pinion bearing is not serviceable, if damaged, replace rack housing.

Fig. 5 Steering Gear Housing Lubricant Points:

Fig. 6 Pinion Oil Seal Installation:

Assemble

1. Lubricate rack teeth, pinion bearing and housing, Fig. 5, with appropriate grease.
2. Lubricate pinion oil seal lips, rack support yoke and rack. Do not plug rack vent holes.
3. Using suitable grease, lubricate rack support bushing, then install bushing to right side of housing engaging bushing tabs to housing slots.
4. If replacing pinion bearing, install new bearing with suitable tool, bearing may be started with a pinion as alignment tool but cannot be seated with pinion. Do not strike pinion with hammer.
5. Install rack through LH side of housing, with teeth facing pinion bore.
6. Install pinion and bearing to housing.
7. Install pinion bearing snap ring with beveled side up (toward oil seal), then oil seal tab spacer tab side down, locating tab in snap ring.
8. Using seal installer tool No. T90P-3504-HH and T81P-3504-P or equivalents, Fig. 6, install oil seal.
9. Install washers and tie rod to rack, then bend tabs downward.
10. Install boots and tie rod ends.
11. Center rack ensuring tie rods are equally extended.
12. Lubricate rack support yoke, then install to housing.
13. Install spacer and yoke spring.
14. Apply sealant to yoke plug threads, then install plug, adjusting nut and locknut to housing.
15. Adjust rack preload as outlined in ADJUSTMENT PROCEDURES/MANUAL STEERING GEARS.