Disassembly and Assembly

DISASSEMBLY
1. Position steering gear in a soft jawed vise.

Rack & Pinion Steering Gear:

2. Disconnect valve body to steering gear hydraulic tubes.
3. Remove steering gear mounting brackets and bushings.

Tubing Seat Locations:

4. Using two screwdrivers and a self tapping screw, remove brass tubing seats from steering gear housing.
5. Using a suitable cold chisel, remove pinion shaft dust boot.
6. Using a No. 40 Torx(R) bit, remove valve body attaching bolts and valve body.
7. Wrap cloth around valve body, then position valve body in vise.

Valve Body:

8. Remove valve body end plug, then remove pivot lever collar.
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.

Rack From Steering Gear Housing Removal:

21. Remove rack from steering gear housing in direction indicated.
22. Using rack inner seal remover T87C-3504-A, or equivalent, remove rack inner guide and seal.

INSPECTION
- Check rack and pinion teeth for wear and damage.
- Position rack in V-blocks and check runout using a suitable dial indicator. Rack runout should not exceed 0.012 in.
- 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.
- Check spool valve for wear and damage and polish with crocus cloth as necessary.

ASSEMBLY
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.

Spool Valve Installation:

2. Position spool valve into valve body.
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. Ensure spherical ends are properly seated.
4. Install valve body end plug.
5. Lubricate inner rack guide and seal with automatic transmission fluid, then install guide and seal using rack inner seal removal tool T87C-3504-A, or equivalent. Push guide and seal into housing until fully seated.

Applying Grease To Rack:

6. Apply grease to rack teeth, then position rack seal protector D83P-3504-K, or equivalent, over rack teeth. When applying grease to teeth, do not cover rack air hole.
7. Apply ATF to rack piston seal, then install seal on the rack, using piston seal replacer T81P-3504-L with pusher T75L-3517-A2 and sizer T81P-3504-K, or equivalents.
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 pinion cover centering 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.

Tightening Outer Bulkhead:

10. Position outer bulkhead to steering gear housing, then wrap bulkhead with a cloth for protection and tighten with a pipe wrench.

Staking Outer Bulkhead To Housing:

11. Stake outer bulkhead to rack housing using a suitable punch.
12. Position lower pinion bearing onto pinion shaft, then tighten and stake nut to pinion shaft.

Positioning Rack & Pinion:

13. Install pinion shaft assembly, with rack and pinion positioned as shown.
14. Apply grease to upper pinion bearing, then install bearing using upper pinion seal replacer T78P-3504-D, or equivalent.
15. Tighten pinion bearing cover.
16. Install and tighten housing locknut.
17. Position valve body and gasket to steering gear housing, then install Torx(R) attaching bolts.
18. Install yoke, spring, adjusting plug and locknut.
19. Adjust preload.
20. After completing adjustment, tighten adjuster plug locknut.
21. Position rack in soft jawed vise, then install tie rods.
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 upper pinion seal replacer T78P-3504-D, or equivalent. 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.