Power Rack & Pinion Steering Gear: Reassembly
- Mark center tooth of rack (eleventh groove) with paint so that mark will be visible in valve bore of housing. Slide Ring Replacer (T74P-3504-G) onto rack until spacer seats on rack piston. Install rubber "O" ring onto rack and seat in groove of rack piston. Install Teflon "O" ring onto rack over tool and seat in rack piston groove over rubber "O" ring.
- Remove plastic insert from new rack seal. Install Rack Seal Protector (T85L-3504-B) over rack teeth. Lubricate protector with power steering fluid. Install rack seal with seal lip against rack piston. Remove seal protector. Install plastic insert in rack seal.
- Pack rack teeth with steering gear grease. Lightly lubricate back of rack with steering gear grease. Lubricate rack seal with power steering fluid. Install Rack Sizing Tube (T78P-3504-M) into end of housing. Carefully push rack assembly into housing until assembly bottoms in housing. Seat rack seal by using a rubber mallet and brass drift to tap end of rack until bottomed in rack housing.
- Using socket wrench and holding rack with adjustable wrench, install left ball socket and tie rod assembly onto rack. Install Rack Seal Protector Sleeve (T74P-3504-J) over right side rack threads. Lubricate protector sleeve with power steering fluid.CAUTION: DO NOT allow rack to travel off center. Excessive travel may cause rack teeth to damage rack seal.
- Lubricate rack oil seal with steering gear grease. Using Rack Seal Replacer (T74P-3504-F), install rack oil seal into bushing retainer. Using protective sleeve, install rack bushing onto rack with seal facing inward. Using Rack Sizing Tube (T78P-3504-M), apply pressure and seat bushing into housing. Install snap ring in right side of housing.
- Using Socket Wrench (T74P-3504-U) and holding rack with adjustable wrench, install right ball socket and tie rod assembly onto rack. Tighten right and left tie rod ball sockets to rack assembly. Rest ball socket on wooden block. To install NEW spring pin, hold spring pin with needle-nose pliers while tapping spring pin in lightly with plastic hammer.
- Fill yoke plug hole with 2 ounces of steering gear grease. Install yoke into housing. Install spring into yoke. Install yoke plug and yoke plug lock nut into housing.
- Using Pinion Bearing Driver (T78P-3504-G), install NEW pinion bearing (if removed). Ensure pinion bearing is seated against shoulder in bore. Lubricate lower input shaft seal with steering gear grease.
- Place seal on Seal Installer (T78P-3504-F), with lip of seal facing toward installer. Support housing on clean surface. Drive lower input shaft seal into housing until seated against shoulder.
- If valve "O" rings were not removed, proceed to step 13). If valve "O" rings were removed, mount pinion end of valve assembly in soft-jawed vise. Lubricate Mandrel (T75L-3517-A1) with power steering fluid. Install mandrel over valve assembly.
- Slide one valve "O" ring over mandrel. Place Slide Ring Pusher (T75L-3517-A2) on mandrel, push down rapidly on ring pusher, forcing "O" ring down into fourth groove of valve sleeve. See Fig 1 . Add one spacer (T75L-3517-A3) to mandrel for each "O" ring, keeping next "O" ring from passing third groove of valve sleeve. Repeat procedure until all "O" rings are installed on input shaft/valve assembly. Lubricate valve sleeve and "O" rings with steering gear grease.
- Install one "O" Ring Spacer (T75L-3517-A3) over input shaft to act as a pilot. Slowly install Sizing Tube (T75L-3517-A4) on input shaft over "O" rings. See Fig 2 . Ensure "O" rings are not distorted as sizing tube is pushed down over them. Allow sizing tube to remain on input shaft for 5 minutes. Remove sizing tube. Ensure "O" rings move freely in grooves and are not damaged.
- Ensure rack is positioned in housing so that right end of rack protrudes 9/16" (14 mm) from socket to housing and paint mark placed on rack before installation is visible through valve bore in housing. See Fig 3 . Place Valve Body Inserter (T78P-3504-C) into top of valve housing. Lubricate input shaft/valve assembly and install into housing. Align "D" shaped flat spot on input shaft facing rearward (when installed in vehicle). Ensure input shaft teeth mesh with rack teeth. Push valve assembly in by hand until fully seated.
- Install Pinion Shaft Torque Adapter (T74P-3504-R) onto input shaft. Install lock nut onto pinion end of valve assembly. Hold pinion shaft with torque adapter. Tighten lock nut to 30-40 ft. lbs. (41-54 N.m). To ensure pinion is centered, count input shaft turns from center to stops. If unequal, remove input shaft, rotate 60 degrees (one tooth) in direction that requires least amount of turns. Reinstall input shaft. Repeat procedure until input shaft is centered.
- Slide input shaft bearing over shaft and into valve bore. Using Bearing Installer (T78P-3504-D), firmly seat bearing into bore. Lightly lubricate input shaft seal with steering gear grease. Install seal with lip facing gear. Drive seal into housing until fully seated. Install snap ring.
- Slide Input Shaft Dust Seal Installer (T85T-3504-CH1) over input shaft. Lubricate inner input shaft dust seal contact area with multipurpose grease. Install inner input shaft dust seal with Seal Installer (T85T-3504-CH2). Remove seal installer from shaft.
- Install and tighten pinion bearing plug to 50 ft. lbs. (67 N.m). Pack outer input shaft dust seal with multipurpose grease. Place outer input shaft dust seal on input shaft and push down until ridge on inside of seal seats in groove on input shaft. Wipe away any excess grease.
- Adjust rack yoke plug preload. See RACK YOKE PLUG PRELOAD under ADJUSTMENTS. To complete reassembly, reverse disassembly procedure. Apply steering gear grease to groove in tie rod where rubber boot is fastened with clamp. Install NEW boot clamps. Install boot clamps on crossmember side of gear with clamp screw axis parallel with yoke plug lock nut.
- Lubricate tie rod end threads with disc brake caliper slide grease before installation on tie rod. Ensure tie rod ends are installed to tie rod using same number of turns required during disassembly procedure.