Input Shaft and Valve Assembly
Fig. 2 Input Shaft And Valve Assembly:
DISASSEMBLY
1. Thoroughly clean input shaft valve housing, yoke locknut, plug and pinion bearing plug.
2. Install steering gear in suitable holding fixture. Do not remove external pressure lines unless they are leaking or damaged. If lines are removed, new Teflon seals must be installed.
3. Using locknut wrench tool No. T78P-3504-H or equivalent, loosen yoke plug locknut, then yoke plug, Fig. 2.
4. Remove pinion bearing plug.
5. Install pinion shaft torque adapter tool No. T74P-3504-R or equivalent on input shaft and remove pinion bearing locknut while holding input shaft. Do not allow rack to reach full travel when loosening or tightening locknut.
6. Using suitable tool, Pry input shaft dust seal from housing, being careful not to damage valve housing surfaces.
7. Remove snap ring, located beneath dust seal, from housing.
8. Install puller tool No. T78P-3504-B or equivalent, on input shaft and tighten nut on tool to remove input shaft and valve assembly, together with input shaft seal and bearing, from housing.
9. To remove lower pinion shaft seal, insert seal remover tool No. T78P-3504-E2 and spacer collar tool No. T86P-3504-J or equivalents, until it bottoms, then hold large nut and tighten small nut on tool until expander fully tightens.
10. Install slide hammer tool No. T50T-100-A or equivalent, in rear of seal remover tool No. T78P-3504-EZ or equivalent, then pull lower pinion shaft seal from housing.
11. Inspect pinion bearing, removing only if replacement is necessary.
12. Remove O-ring seals only if replacement is necessary.
ASSEMBLY
1. If pinion bearing was removed, place lower pinion bearing on bearing installation tool No. T78P-3504-G, or equivalent and position bearing and tool in lower housing.
2. Support housing with wooden block and drive pinion bearing into housing until it is seated against shoulder in bore.
3. Coat lower pinion oil seal with suitable lubricant, place seal on installation tool with seal lip facing toward tool, support housing on clean flat surface and drive seal until it is seated against shoulder.
4. If O-ring seals were removed, proceed as follows:
a. Mount pinion end of valve assembly in suitable vise.
b. Lubricate mandrel tool No. T75L-3517-A1 or equivalent with suitable lubricant and install tool over valve assembly, then slide one valve sleeve O-ring over tool.
c. Slide ring pusher tool No. T75L-3517-A2 or equivalent over mandrel and push down rapidly to force O-ring down ramp into fourth groove of valve sleeve.
d. Repeat above step three more times, adding one spacer under mandrel each time.
e. Apply suitable lubricant to sleeve and O-rings.
f. Install one spacer T75L-3517-A3 or equivalent over input shaft, then slowly install sizing tube T75L-3517-A4 or equivalent over sleeve valve end of input shaft onto valve sleeve O-rings, ensuring that O-rings are not being bent over as sizing tube is slid over them.
g. Remove sizing tube and check condition of O-rings, ensuring they turn freely in grooves. If only valve was serviced and rack was not moved while valve was out, skip step 5.
5. If rack was removed and marked with paint, position rack so that paint mark is centered in valve bore. If rack was not removed, position rack in housing so that right end of rack protrudes 9/16 inch from socket to housing.
6. Insert valve body insertion tool No. T78P-3504-C or equivalent in top of valve housing, lining up D-flat on input shaft 180° from yoke plug hole center and insert valve assembly in bore. The D-flat must point straight to the rear when the gear is installed in the vehicle with the gear in the on-center position. If necessary, rotate input shaft slightly from side to side to mesh pinion to rack teeth. Push valve assembly in by hand until properly seated.
7. Install suitable tool on input shaft and check if pinion is centered by rotating input shaft and counting number of turns from center to each stop. If number of turns is not equal, pull valve assembly out far enough to free pinion teeth, rotate input shaft 60° in direction that requires least turns and reinsert valve assembly. Repeat procedure as necessary until pinion is centered.
8. With rack away from stops, install nut on pinion end of valve assembly, hold input shaft with shaft holding tool No. T74P-3504-R, or equivalent and torque nut to 30-40 ft. lbs.
9. Position input shaft bearing over shaft and in bore, then, using suitable tool, drive bearing into bore until firmly seated.
10. Coat input shaft seal with suitable lubricant.
11. Install input shaft seal with lip toward gear housing.
12. Install input shaft seal over seal protector tool so seal lip faces valve.
13. Drive seal into bore until seated.
14. Install snap ring in valve bore.
15. Coat input shaft with suitable lubricant in dust seal contact area.
16. Install input shift seal tool No. T85T-3504-CH1 or equivalent over input shaft.
17. Install input shaft dust seal and drive into position with suitable tool.
18. Remove seal tool from seal and input shaft.
19. Install bearing cap, torquing to 50 ft. lbs.
20. Adjust rack yoke plug preload.