Power
Fig. 7 Steering Gear Holding Fixture:
Fig. 8 Exploded View Of Steering Gear:
Fig. 9 Pinion Shaft Locknut Removal:
DISASSEMBLE
1. Install steering gear to rack holding fixture tool No. D87P-3504-B or equivalent, Fig. 7.
2. Place installation alignment marks on tie rod end, jam nut and tie rod.
3. Remove tie rod ends and jam nuts, Fig. 8.
4. Remove boot clamps, then remove boots.
5. Remove tie rods, then pinion shaft dust seal.
6. Remove pinion shaft snap ring, then using yoke locknut wrench tool No. T81P-3504-G or equivalent, remove yoke plug locknut.
7. Using yoke plug adapter tool No. T87P-3504-G or equivalent, remove yoke plug.
8. Remove spring, then using pinion plug spanner wrench tool No. T90P-3504-AH or equivalent, remove lower pinion bearing plug.
9. Using pinion torque adapter tool No. T86P-3504-K or equivalent, to hold pinion shaft, remove pinion shaft locknut, Fig. 9.
10. Using valve body puller bridge tool No. T86P-3504-D and spool valve puller tool No. T81P-3504-T or equivalents, remove pinion shaft seal, bearing and shaft from housing.
11. Remove four valve Teflon O-rings and discard.
Fig. 10 Pinion Seal Removal:
Fig. 11 Rack Bushing Seal Removal:
12. Expand lower pinion seal remover tool No. T86P-3504-F or equivalent to 1.08-1.13 inch (27.4-28.7 mm), then using lower pinion seal remover guide tool No. T86P-3504-J or equivalent, seat seal remover to seal, then install impact slide hammer tool No. T50T-100A or equivalent, then remove pinion seal, Fig. 10.
13. The middle pinion bearing is not serviceable, and should not be removed from housing. If bearing is worn or damaged, replace short rack assembly.
14. Remove rack snap ring, rack end plate, bushing and rack from housing.
15. Using piston pin remover tool No. T68P-6135-A7 or equivalent, remove lower pinion bearing.
16. Using impact slide hammer tool No. T50T-100-A and rack oil seal remover tool No. T87P-3504-A or equivalent, remove and discard inner seal.
17. If plastic insert is removed and seal is left in housing, repeat step 17 for seal removal.
18. Using rack bushing tool No. T87P-3504-L, rack oil seal remover tool No. T87P-3504-A and impact slide hammer tool No. T50T-100-A or equivalents, remove rack bushing seal, Fig. 11.
19. Remove rack bushing O-ring and discard.
20. Remove rack piston Teflon seal and discard.
21. Remove rack piston O-ring and discard.
22. If yoke support requires replacement, using suitable drift, punch out expansion plug, then remove yoke support and discard support and expansion plug.
INSPECTION
1. Inspect pinion shaft bearing for fit on shaft.
2. Check fluid passages for obstruction or leakage.
3. Inspect housing for cracks and stripped threads.
4. Check mating surfaces for burrs.
5. Inspect valve and piston bores for scoring.
6. Ensure pinion shaft rotates freely.
7. Inspect piston rack and pinion shaft teeth for nicks and burrs.
ASSEMBLE
Fig. 12 Rack Piston O-ring & Seal Installation:
1. If required, install yoke support and expansion plug.
2. Using piston seal replacer tool No. T81P-3504-L or equivalent, install rack piston O-ring, then Teflon seal, Fig. 12.
3. Separate steering gear inner seal plastic insert and save for later installation.
4. Install rack oil seal protector tool No. T87P-3504-H or equivalent, over rack, then install plastic insert and inner seal to piston, then remove seal protector.
5. Snap plastic insert into inner seal.
6. Using suitable steering gear lubricant, pack steering rack teeth, then apply light lubricant to rack yoke contact area.
7. Using suitable power steering fluid, lubricate piston seal and gear inner seal outer edge.
8. Install rack piston seal sizer tool No. T81P-3504-K or equivalent, to end of steering gear housing, then install rack.
9. Using suitable punch and plastic hammer, drive end of rack to seat inner seal.
10. Install rack bushing O-ring, then using rack oil seal replacer tool No. T81P-3504-C or equivalent, install rack bushing seal.
Fig. 13 Rack Bushing & End Plate Installation:
Fig. 14 Valve Seal Installation:
11. Using rack oil seal protector tool No. T87P-3504-H or equivalent, over rack, install rack bushing and end plate, Fig. 13.
12. Install rack attaching snap ring to housing.
13. Using pinion bearing replacer tool No. T90P-3504-BH and driver handle tool No. T80T-4000-W or equivalents, install lower pinion bearing.
14. Using lower pinion seal replacer tool No. T87P-3504-C and handle T87P-3504-D or equivalents, install pinion seal.
15. Install valve seal spacer set tool No. T90P-3504-FH or equivalent, then using mandrel tool No. T75L-3517-A1 and ring pusher tool No. T75L-3517-A2 or equivalents, install valve Teflon seal, Fig. 14.
16. Size valve Teflon seals with Teflon ring sizer tool No. T87P-3504-F or equivalent.
17. Center rack in housing.
18. Install Teflon ring sizer tool No. T87P-3504-F or equivalent, to valve housing bore. Center of pinion shaft V-flat surface must be in 9 o'clock position.
19. Install pinion shaft until teeth mesh with rack teeth, center of pinion shaft V-flat will be in 9 o'clock position, push shaft by hand until fully seated.
20. Using pinion torque adapter tool No. T86P-3504-K or equivalent, turn pinion shaft, count number of turns from center to each stop, ensure pinion shaft is centered, if number of turns is not equal, remove shaft and reinstall.
21. Using pinion torque adapter tool No. T86P-3504-K or equivalent, hold pinion shaft, then tighten shaft locknut to specifications.
22. Using pinion plug spanner wrench tool No. T90P-3504-AH or equivalent, install lower pinion bearing plug, tighten to specifications.
23. Using upper pinion bearing/seal replacer tool No. T78P-3504-D and bearing spacer ring tool No. T90P-3504-CH or equivalents, install pinion shaft bearing.
24. Install input shaft seal protector tool No. T81P-3504-P or equivalent, over pinion shaft.
25. Using upper pinion bearing/seal replacer tool No. T78P-3504-D and seal spacer ring tool No. T90P-3504-DH or equivalents, install pinion shaft.
26. Install snap ring to housing.
27. Using pinion dust seal replacer tool No. T85T-3504-CH1 or equivalent, install pinion shaft dust seal.
28. Install yoke plug bore spring, then using yoke plug adapter too No. T87P-3504-G or equivalent, install yoke plug and tighten to specifications.
29. Using yoke locknut wrench tool No. T81P-3504-G or equivalent, tighten yoke plug locknut to specifications.
30. Apply ESE-MAG203-A2 to tie rods, then install to rack and tighten to specifications.
31. Install and clamp boots.
32. Install jam nuts, then tie rod ends and tighten to specifications.