Gear Housing, Rack, Yoke Plug, Rack Bushing, and Seal

DISASSEMBLY
1. Remove tie rods and socket assemblies from both ends of rack, also remove input shaft and valve assembly from gear housing.
2. Remove yoke plug and spring. Yoke cannot be removed at this time.

Snap Ring Removal:

3. Working from righthand side of gear, push rack in just far enough to enable removal of snap ring.
4. Slowly pull rack out of righthand side of housing until rack position contacts aluminum rack bushing. Apply pulling effort and remove rack from housing. Do not hammer on rack until bushing is withdrawn from housing.
5. Using rack oil seal remover T87P-3504-A, or equivalent, remove internal high pressure oil seal.
6. Remove plastic O-ring and rubber O-ring from rack piston.
7. Insert rack bushing into rack bushing holder T78P-3504-L, or equivalent, seal end first. Place tool and bushing into vise.
8. Using rack oil seal remover T87P-3504-A, remove seal.
9. Remove rubber O-ring from rack bushing.

Yoke & Expansion Plug Removal:

10. Use a drift or punch to knock out yoke, along with expansion plug.

ASSEMBLY
1. Coat new yoke with steering gear grease. Install through expansion plug opening, rack bearing surface up.
2. Slide ring installation tool T81P-3504-L, or equivalent, over plain end of rack up to piston.
3. Remove plastic insert from rack seal and save.
4. Install seal protector over rack teeth.
5. Lubricate rack seal protector and rack with power steering fluid.
6. Install seal with lip toward piston.
7. Install plastic insert in rack seal. Remove seal protector.
8. Apply steering gear lubricant to rack teeth and power steering fluid to the piston seal and rack seal outside diameter.
9. Install seal sizing tool T87P-3504-F, or equivalent, into end of gear housing.
10. Ensure yoke is positioned correctly, then install rack, ensure not to scratch housing piston bore.
11. Carefully push piston through sizing tool. Continue pushing on rack until it bottoms. Remove sizing tool.
12. Seat rack seal with rack by driving end of rack with a drift and plastic mallet.
13. Install lefthand tie rod hand tight to prevent potential inner seal damage due to excessive rack travel.
14. Center rack in housing.
15. Install rubber O-ring on aluminum rack bushing.

Rack & Bushing Seal:

16. Apply power steering fluid to outer rack seal and install seal in rack bushing. Seal lip spring must face inside of bushing.
17. Install rack seal protector T81P-3504-N, or equivalent, over threads on righthand side of rack. Apply power steering fluid to protective sleeve.
18. Start bushing, seal side out, on rack. Position bushing into housing. Place end plate against rack bushing. Apply hand pressure to end plate and rack bushing until bushing seats in gear housing. If rack bushing will not seat with hand pressure, a 1 1/8 inch deep socket and a plastic mallet may be used to tap bushing in place.
19. Install retaining ring and remove protective sleeve.
20. Install tie rod assemblies as previously described.
21. Install input shaft and valve assembly.
22. Support gear on wood block at yoke plug opening. Using a 1 1/4 inch bar with a flat end, flatten expansion plug until flat portion is approximately 1/2 to 3/4 of total plug diameter. Do not flatten plug completely or it may fall out.
23. Install spring, plug and locknut. Adjust yoke plug preload.
24. Fully extend lefthand end of rack. Apply two ounces gear lubricant to pack rack teeth. Place any remaining grease into lefthand end of gear housing.
25. Install bellows, breather tube and bellows clamps.
26. Install jam nuts and tie rod ends on tie rods.