Oil Seals Replacement
Fig. 3 Gear Housing:
DISASSEMBLY
1. Remove tie rod, socket assemblies, input shaft and valve assembly.
2. Using suitable puller, remove yoke plug locknut, Fig. 3.
3. Remove yoke plug from housing.
4. Remove yoke spring and yoke from gear housing. Remove yoke by gripping on guide post with pair of pliers.
5. Working from right end of gear, push rack into housing far enough to gain access to snap ring.
6. Remove snap ring from right end of gear housing.
7. Using hammer and brass drift, slowly drive rack out of right side of housing together with rack bushing, then remove rack from housing.
8. To remove internal high pressure rack oil seal, insert oil seal remover tool No. T78P-3504-J or equivalent into housing until it bottoms.
9. Activate expander with wrench until expander fully tightens against oil seal.
10. Insert slide hammer into tool and pull seal from housing. Discard seal. On first attempt, plastic insert may pull out of seal, leaving seal in housing. Repeat procedure until seal is removed.
11. Using suitable tool, remove plastic O-ring and rubber O-ring from rack piston.
12. Remove rack bushing seal by gripping seal in vise and squeezing seal to distort it, then pry out with screwdriver.
ASSEMBLY
Fig. 4 Installing Plastic Insert In Rack Seal:
1. Mark center tooth (11th tooth) on rack so that mark will be visible in valve bore.
2. Slide ring replacer tool No. T74P-3504-G or equivalent on rack until it seats on piston, then install rubber O-ring in rack piston groove.
3. Slide plastic O-ring over tool into piston groove over rubber O-ring.
4. Remove and retain plastic insert from rack seal.
5. Install rack seal protector tool No. T85L-3504-B or equivalent over rack teeth.
6. Lubricate rack and tool with suitable lubricant.
7. Install seal so that lip faces toward piston. Push seal all the way against piston. Remove rack seal protector.
8. Install plastic insert into rack seal, Fig. 4.
9. Pack rack teeth with suitable lubricant and apply light coat of lubricant to yoke contact area in back of rack teeth.
10. Apply suitable lubricant to to piston seal and rack seal O. D.
11. Install teflon ring sizing tool No. T78P-3504-M or equivalent into end of gear housing.
12. Install rack, being careful not to scratch housing piston bore.
13. Carefully push piston through sizing tool, pushing on rack until it bottoms, then remove sizing tool.
14. Seat rack seal with rack by driving end of rack with suitable tool. Do not remove rack.
15. Install left tie rod and ball socket on rack and hand tighten.
16. Thread rack sleeve protector T74P-3504-J or equivalent over threads on right side of rack and coat sleeve with suitable lubricant. Rack must not move too far from center as excessive travel may cause rack teeth to cut left inner oil seal.
17. Apply suitable lubricant to outer rack oil seal and, using suitable tool, install high pressure oil seal in rack bushing.
18. Apply suitable lubricant to short protective sleeve on rack and seal O. D. on rack bushing.
19. Start bushing on rack with seal facing inward and pass bushing and seal over protective sleeve and into housing bore. Using Teflon seal sizing tool No. T78P-3504-M or equivalent, apply hand pressure to rack bushing until bushing seats in gear housing. If rack bushing will not seat with hand pressure, a 1-1/8 inch, 12 point or larger deep socket and a plastic mallet may be used to tap bushing in place.
20. Install snap ring in right end of gear housing.
21. Install right tie rod assembly. Torque both tie rod sockets simultaneously to 55-65 ft. lbs. by holding one and turning the other.
22. Install coiled pins in sockets by lightly tapping with hammer until seated.
23. Fill yoke plug hole with 2 ounces of suitable lubricant.
24. Install yoke plug in gear housing.
25. Install yoke in gear housing.
26. Install yoke spring in yoke.
27. Start yoke plug and locknut in gear housing.
28. Install input shaft and valve assembly.
29. Adjust rack yoke plug preload.
30. Apply suitable lubricant to under-cut in tie rods where bellows clamp to tie rods.
31. Install bellows and breather tube, using new clamps.
32. Install clamps retaining bellows to tie rods.
33. Install jam nuts and tie rod ends on tie rods.