W/Engine Speed Sensing Power Steering
1. Mounting bracket and rubber:a. Install mounting rubber.
b. Tap mounting bracket on with plastic hammer.
2. O-ring and seal ring:
a. Apply transmission fluid to O-ring and seal ring.
b. Install O-ring in ring groove of rack.
c. Install seal ring in groove of rack. Be careful not to cut or otherwise damage edge of seal ring.
d. Insert needle bearing and tool 49G032313 or equivalent into housing.
e. Set housing on press and press in bearing.
3. Oil seal:
a. Apply grease to end of tool 49G032313 or equivalent.
b. Apply transmission fluid to oil seal, then set seal on tool.
c. Insert oil seal and tool into housing.
d. Set housing on press and press in seal.
4. Spacer and pinion housing side oil seal:
a. Apply grease to flat surface of spacer.
b. Connect oil seal to grease coated surface of spacer.
c. Apply transmission fluid to inside and outside of spacer and oil seal.
d. Set spacer and oil seal on tool 49G032310 or equivalent.
e. Insert tool from tube side.
f. Install and tighten, tool 49G032311 or equivalent, nut against tube.
g. Turn tool shaft in as far as it will go to push in seal and spacer, then remove tool.
5. Rack:
a. Apply lithium base grease to friction surface and teeth of rack.
b. Slide tool 49G032305 or equivalent over rack and slide it in from tube side, then remove tool.
6. Oil seal (rack):
a. Apply transmission fluid to oil seal and slide it on rack.
b. Set tool 49G032304 or equivalent on rack.
c. Turn tool as far as it will go and push oil seal into tube, then remove tool.
7. Rack bushing:
a. Install rack bushing assembly in rack housing, torquing to 65-72 ft. lbs.
b. Stake rack housing at two points, approximately .06 inch (1.5mm) from end, with a hammer and center punch.
8. Hermetic inspection:
a. Connect tools 49G032317 and 49G032319, or equivalents, to cylinder housing, then connect vacuum pump to tools.
b. Apply 15.7 inch Hg vacuum and ensure vacuum is held for at least 30 seconds. If not, check seal and assembly.
9. Lower bearing:
a. Secure gear housing in vise so that lower bearing bore faces upward.
b. Apply transmission fluid to lower bearing, then install it in housing.
c. Press bearing into gear housing with the housing cover, tightening cover until tightening force suddenly increases.
10. Pinion shaft assembly:
a. Apply lithium base grease to teeth of pinion shaft.
b. Apply transmission oil to seal ring and friction surface of control valve.
c. Install pinion shaft in housing. Be careful not to damage oil seal or edge of seal ring and control valve.
11. Apply transmission fluid to upper bearing, then install it.
12. Oil seal:
a. Apply transmission fluid to oil seal and fill inside lip with lithium base grease.
b. Slide tool 49G032309 or equivalent over serrations of pinion shaft assembly.
c. Slide oil seal over tool and position it in housing.
d. Tap oil seal with tool 49G032308 or equivalent until snap ring installation groove in housing is just visible. Apply uniform force to oil seal when installing.
13. Install snap ring, ensuring it is correctly seated in ring groove.
14. Locknut:
a. Temporarily install tie rod on tube side of rack.
b. Install locknut and turn it until tie rod contacts tube.
c. Torque locknut to 33-40 ft. lbs.
15. Housing cover:
a. Apply thread sealant to housing cover threads.
b. Install housing cover, torquing to 33-40 ft. lbs.
c. Stake between rack housing and housing cover at two points with a center punch.
16. Pressure pad:
a. Secure gear housing in vise so that pressure pad position faces upward.
b. Apply lithium base grease to rack sliding surface of pressure pad, then install it in housing.
c. Install pressure pad.
17. Adjust cover:
a. Set rack in center position.
b. Torque adjust cover to 7.2 ft. lbs., then loosen it.
c. Torque adjust cover to 3.6-4.4 ft. lbs., then loosen 45°.
d. Apply thread sealant to exposed threads of adjust cover.
e. Install locknut, torquing to 36-43 ft. lbs.
18. Tie rod:
a. Secure rack in vise.
b. Install tie rod on rack, torquing to 90-105 ft. lbs.
c. Tap in a new roll pin.
19. Boot:
a. Apply grease to inner surface of small end of boot.
b. Install boot. Wrap a new wire around large end of boot two times and then twist it 4 or 4-1/2 times. Bend twisted part toward mounting bracket. Be careful not to break boot wire.
20. Align match marks and install tie rod ends.
21. Secure mounting bracket in vise so that oil pipe connections face upward, then install pipes.
22. Install pressure switch O-ring in gear housing, then install oil pressure switch, torquing to 23-27 ft. lbs.