Rack Piston/Valve Assembly

RACK PISTON/VALVE ASSEMBLY

REMOVAL





1. Remove the steering gear.
2. Clean exposed end of pitman shaft and housing with a wire brush.
3. Rotate the stub shaft with a wrench from stop to stop and count the number of turns.
4. Center the stub shaft by rotating it from the stop 1/2 of the total amount of turns.





NOTE: The pitman shaft will not clear the housing if it is not centered.

5. Remove pitman shaft cover bolts and remove the shaft assembly.
6. Remove the pitman shaft cover O-ring.





7. Remove stub shaft housing bolts.





8. Remove the housing from the stub shaft.





9. Remove stub shaft housing O-rings.





10. Remove the rack piston/valve assembly retaining ring with snap ring pliers.





11. Pull the rack piston/valve assembly out of the gear housing.

NOTE: If the rack piston is damage the gear assembly must be replaced.





12. Remove teflon rings and O-ring from the rack piston/valve assembly.

CAUTION: The rack piston teflon ring and O-ring must be replaced whenever the assembly is removed from the housing.

INSTALLATION
1. Lubricate new O-ring and teflon rings with power steering fluid and install on the rack piston/ valve assembly.
2. Lubricate the rack piston/valve assembly with power steering fluid.
3. Slide the assembly into the gear housing.
4. Install new stub shaft housing O-rings and install the housing. Tighten the housing bolts to 62 Nm (46 ft. lbs.).
5. Install new O-ring on the pitman shaft cover.
6. Install the pitman shaft into the gear housing.
7. Install the pitman shaft cover bolts and tighten to 62 Nm (46 ft. lbs.).
8. Perform over-center rotation torque adjustment.
9. Install the steering gear.
10. Fill the power steering pump.