Assembly

Fig. 11 Installing spool valve. Power rack & pinion steering gear:

1. Install replacement O-rings on spool valve. Apply molybdenum disulfide grease to spool valve pivot lever hole. Lubricate remainder of spool valve with automatic transmission fluid.
2. Position spool valve into valve body, Fig. 11.
3. Apply molybdenum disulfide grease to pivot lever hose in valve body and to ends of pivot lever collar and bushing, install pivot lever into valve housing, ensuring spherical ends are properly seated.

Fig. 7 Exploded view of power rack & pinion steering gear:

4. Install valve body end plug, Fig. 7.
5. Lubricate inner rack guide and seal with automatic transmission fluid, then install guide and seal using tool No. T87C-3504-A or equivalent. Push guide and seal into housing until fully seated.

Fig. 12 Applying grease to rack. Power rack & pinion steering gear:

6. Apply grease to rack teeth, then position rack seal protector D83P-3504-K or equivalent over rack teeth. When applying grease teeth, do not cover rack air hole, Fig. 12.
7. Using tool T81P-3504, install rack piston seal.
8. Lubricate rack piston and housing cylinder bore with automatic transmission fluid, then slide rack into housing until fully seated. Remove rack seal protector from rack teeth.

*** UPDATED BY TSB# 90-6B-06

9. Install the inner guide only with tool T87C-3504-A, into the housing as far as it will go. Remove plastic retainer from the inner rack seal.

Fig. 13 Tightening outer bulkhead. Power rack & pinion steering gear:

***UPDATED BY TSB# 90-6B-06

10. Apply grease to the rack teeth. Install rack seal protector D83P-3504-K on the rack and install the inner rack seal on rack next to piston. Remove tool T87C-3504-A, re-install plastic retainer back on to inner rack seal. Fig. 13.

Fig. 14 Staking outer bulkhead to housing. Power rack & pinion steering gear:

11. Stake outer bulkhead to rack housing using a suitable punch, Fig. 14.
12. Position lower pinion bearing onto pinion shaft, then tighten and stake nut to pinion shaft. Prior to staking, torque pinion nut to 28.9 to 36.2 ft. lbs.

Fig. 15 Positioning rack & pinion. Power rack & pinion steering gear:

*** UPDATED BY TSB# 90-6B-06

13. Slide the rack as far as it will go into the housing, using the rack to properly position the inner seal and guide. (The seal protector has already been removed.) Fig. 15.
14. Apply grease to upper pinion bearing, then install bearing using tool No. T78P-3504-D.
15. Torque pinion bearing cover to 4.3 to 7.8 inch lbs., then loosen 10 to 20 degrees.
16. Install and torque housing locknut to 28.9 to 36.2 ft. lbs.
17. Position valve body and gasket to steering gear housing, then install Torx attaching bolts.
18. Install yoke, spring, adjusting plug and locknut. Torque adjusting plug to 39.1 to 47.7 inch lbs., then loosen 45 degrees.
19. Using an inch lb. torque wrench, measure pinion rotating torque. Pinion rotating torque should be .52 to 1.3 inch lbs. If pinion rotating torque is not within limits, adjust by loosening or tightening adjuster plug.
20. After completing adjustment, torque adjuster plug locknut to 28.9 to 36.2 ft. lbs.
21. Position rack in soft jawed vise, then install tie rod and torque ball unit to 43.4 to 57.9 ft. lbs.
22. Stake tie rod tab washer at two locations.
23. Install tie rod boots over tie rod and steering gear housing, then install lock wires and clamps.
24. Install tie rod ends and jam nuts, aligning marks made during disassembly.
25. Wrap electrical tape around pinion shaft, then apply grease to shaft. Apply grease to pinion shaft seal lips, then install seal using tool T78P-3504-D. After seal has been installed, remove tape from pinion shaft.
26. Install rack support bushings and brackets.
27. Install replacement tubing seats, then connect hydraulic tubing to steering gear and valve body.