Input Shaft and Valve Assembly

DISASSEMBLY
1. Thoroughly clean steering gear housing, then mount gear in holding fixture T57L-500-B, or equivalent.
2. Do not remove the external pressure lines unless damaged or leaking. Loosen yoke plug locknut and yoke plug to relieve preload on rack.

Pinion Bearing Locknut Removal:

3. Remove pinion bearing plug, then using pinion shaft torque adapter T74P-3504-R, or equivalent, to hold input shaft in position and remove pinion bearing locknut with a 11/16 inch socket. Discard pinion bearing locknut and use a new nut at assembly.
4. Using a suitable tool, pry input shaft dust seal out of valve housing. Use care not to damage valve housing.
5. Remove snap ring from valve housing.

Input Shaft & Control Valve Assembly Removal:

6. Attach valve body puller (bridge) T86P-3504-B and valve body puller (screw) T78P-3504-B, or equivalent, and remove input shaft seal, input shaft and valve body.
7. Using lower pinion seal remover T78P-3504-E, or equivalent, and a suitable slide hammer, remove lower pinion shaft seal.
8. Remove pinion bearing from gear housing using puller attachment T58L-101-A, or equivalent, and a suitable slide hammer.
9. If necessary, remove O-rings from input shaft and valve assembly. Remove O-rings by pushing rings to one side and inserting a small pointed knife to cut ring off.

ASSEMBLY
1. Support valve housing with a wooden block, then using lower pinion bearing replacer T78P-3504-G, or equivalent, install pinion bearing in gear bore. Seat bearing against shoulder in bore.
2. Apply grease to pinion oil seal, then position seal on lower pinion seal replacer tool T86P-3504-G, or equivalent, with seal lip facing towards tool. Install seal in valve bore, seating seal against shoulder.
3. Position pinion end of valve assembly in a soft jawed vise.
4. Install mandrel T75L-3517-A1, or equivalent, over sleeve, then slide one valve sleeve ring over mandrel.
5. Slide pusher tool T75L-3517-A2, or equivalent, over the mandrel, then rapidly push down on the pusher tool to force ring down into fourth groove of valve sleeve. Add one spacer T75L-3517-A3, or equivalent, under mandrel, to align mandrel with the next groove on the valve sleeve. Repeat procedure until all sleeve rings have been installed.
6. Apply a light coat of power steering fluid to sleeve and sleeve rings.
7. Install one spacer over input shaft, then slowly install sizing tube T75L-3517-A4, or equivalent, over sleeve valve end of input shaft onto valve sleeve rings.
8. Remove sizing tube and check condition of sleeve rings. Ensure rings turn freely in grooves.
9. If rack is removed, position rack so that mark made during disassembly is centered in valve bore. If rack was not removed, position rack in housing so that three teeth protrude from lefthand end of housing.

Input Shaft Alignment:

10. Align input shaft flats as shown.
11. Using pinion shaft torque adapter T86P-3504-K, or equivalent, to turn input shaft, count number of turns from center to each stop. This should be approximately 1 1/2 turns. If number of turns is unequal, pull valve assembly out of housing far enough to free pinion teeth. Rotate input shaft 60° (one tooth) in direction which required fewer turns from center to stop. Reinstall valve assembly and check if gear is centered.
12. While holding input shaft with pinion shaft torque adapter tool T74P-3504-R, or equivalent, install a new pinion bearing locknut on pinion end of valve assembly. The rack must be away from stops when installing locknut.
13. Lubricate input shaft bearing, then install bearing into valve bore and seat with upper pinion bearing seal replacer T78P-3504-D, or equivalent.
14. Lubricate input shaft seal, then install seal with seal lip facing valve assembly.
15. Install snap ring into valve bore.
16. Coat input shaft in area of dust seal with Lubriplate, or equivalent, then install dust seal and seat seal with upper pinion bearing seal replacer T78P-3504-D, or equivalent.
17. Install steering gear housing cap.
18. Fill yoke housing with 2 ounces of lubricant, then install yoke. The yoke must seat against the rack with finger pressure, if not check for burrs in yoke housing.
19. Install yoke spring and yoke plug. Adjust yoke bearing preload.
20. Install yoke plug locknut.
21. If the external pressure lines were removed in step two, they must be replaced with new pressure lines. Remove the copper seals from the pressure ports previous to installation of new lines.