Input Shaft and Valve Assembly

NOTE: The only serviceable component of the input shaft and valve assembly are the four plastic O-rings.

DISASSEMBLY
1. Clean exterior of steering gear thoroughly.
2. Mount gear in holding fixture D87P-3504-B, or equivalent. Do not hold gear in vise.
3. Do not remove external pressure lines unless they are leaking.
4. Loosen yoke plug locknut to relieve preload on rack.
5. Remove pinion bearing plug using pinion plug spanner T83P-3504-AH, or equivalent.

Pinion Bearing Locknut Removal:

6. While holding input shaft, remove and discard pinion bearing locknut.
7. Pry out input shaft dust seal using an appropriate tool.
8. Remove snap ring, located under dust seal, from housing.

Valve Body Puller Tool:

9. Attach valve body puller T86P-3504-D and valve body puller T81P-3504-T, or equivalent, to input shaft.
10. Turn nut to remove valve. Input shaft seal and bearing will come out with valve body.

Lower Pinion Seal Removal Tool:

11. Remove lower pinion shaft seal using Seal Removal Tools T86P-3504-F, T86P-3504-J and T50T-100-A, or equivalents.
12. Remove pinion bearing from gear housing using puller attachment T58L-101-B, or equivalent.
13. Remove O-rings by pushing rings to one side, then inserting small pointed tool under each ring, and cutting ring off.

ASSEMBLY
1. Install steering gear pinion bearing in gear housing using lower pinion bearing replacer T81P-3504-H, or equivalent. Seat bearing against shoulder in bore. Support valve housing when seating pinion bearing.
2. Apply Steering Gear Grease C3AZ-19578-A, or equivalent, to pinion seal and place it on lower pinion seal replacer T87P-3504-C, or equivalent, with seal lip toward tool.

Plastic Valve Rings Installation:

3. Install short spacer over input shaft of valve assembly. Install mandrel part of valve seal installer T75L-3517-A, or equivalent, over shaft and spacer. Mandrel will line up with second groove from input shaft.
4. Lubricate mandrel with power steering fluid. Place one valve sleeve over mandrel. Rapidly push ring down with pusher tool. Ring will drop into proper groove.
5. Install long spacer over input shaft. Mandrel will line up with first groove on input shaft. Repeat step 4.
6. Repeat steps 3 through 5 sliding mandrel over the pinion end of valve.
7. After four valve sleeves are installed, apply a light coat of steering gear grease to sleeve and rings.

Seal Sizing Tool Installation:

8. Slowly install seal sizing tool T87P-3504-F, or equivalent, over valve sleeve rings. Ensure rings are not being bent over or out of grooves as tube is slid over them.
9. Continue sliding sizing tool over rings until it has passed over rings and comes off other end. Ensure rings turn freely in the grooves.

Positioning Rack In Housing:

10. Position rack in housing so four complete tooth spaces protrude from lefthand end of housing, then move rack slightly, as necessary, to center tooth visible in valve bore.
11. Position seal sizing tool in valve housing bore.
12. Position D-flat on input shaft at the 3 o'clock position and insert valve assembly into bore. The D-flat surface must be at the 3 o'clock position in the vehicle with the gear on center position. Rotate input shaft slightly, if necessary, to mesh the pinion with the rack teeth.
13. Push valve assembly in by hand until seated properly, then remove sizing tool.

Proper Input Shaft Position:

14. Using input shaft torque adjuster T81P-3504-R, or equivalent, count total turns, stop to stop. From one stop, back off half the total of turns. D-flat should be as shown. If not, repeat steps 11 through 13.
15. Install bearing assembly in valve bore and seat with input shaft and seal installer T78P-3504-D, or equivalent.
16. Install input shaft protector T81P-3504-P, or equivalent, over input shaft and install input shaft seal with lip spring toward valve.
17. Remove seal protector and seat seal.
18. Install retaining snap ring in valve bore.
19. Apply a generous amount of grease over top of input shaft pressure seal around input shaft.
20. Install dust seal and seat with seal installer T78P-3504-D, or equivalent.
21. Install nut on pinion end of valve assembly. Holding input shaft, tighten nut. Rack must be in center position when tightening.
22. Install steering gear pinion bearing cap.
23. Set rack preload.