Manual
Fig. 1 Exploded view of manual rack & pinion steering gear:
1. Position steering gear in a soft jawed vise, then remove mounting brackets and mounting bushings, Fig. 1.
2. Place alignment marks on tie rod, tie rod end and jam nut so they can be installed in the same position.
3. Remove tie rod ends and jam nuts from tie rod.
4. Remove tie rod boot from steering gear housing, then using a suitable chisel, uncrimp tabs on tie rod washer.
5. Position rack in soft jawed vise, then using a suitable wrench loosen ball housing and remove tie rod from rack. Remove tie rod from other side of rack in the same manner.
6. Remove locknut, adjusting cover and adjusting bolt from steering gear housing.
7. Using suitable pliers, remove support yoke, spring and shim from steering gear housing.
8. Mounting steering gear housing in soft jawed vise, then using a suitable screwdriver, pry pinion seal from housing. When removing seal, use care not to damage pinion shaft. It maybe necessary to remove steering gear housing from vise and shake pinion seal spacer from housing.
9. Remove pinion bearing snap ring, then pull pinion assembly out of upper bearing side of steering gear housing. If difficulty is encountered when removing pinion assembly, use tool T78P-3504-B to remove pinion assembly.
Fig. 2 Removing rack from steering gear housing. Manual rack & pinion steering gear:
10. Pull rack out through pinion side of steering gear housing, Fig. 2.
11. Remove steering gear housing support bracket and bushing, the remove pinion lower bearing using tools D80L-100-L and T50T-100A or equivalent, if necessary.
12. Using a suitable screwdriver push inward on lock tabs of rack support bushing, then using tools D80L-100-R and T50T-100-R or equivalent, remove bushing from housing.
13. After bushing has been removed, clean steering gear housing.
INSPECTION
Check rack and pinion teeth for wear and damage. Position rack in V-blocks and check run-out using a suitable dial indicator. Rack run-out should not exceed .012 inch. Check pinion bearing for looseness and wear. If rack, pinion or pinion bearings are found to be unsatisfactory, the rack and pinion must be replaced as a set. Check steering gear housing for wear and damage. Check tie rod ball units for looseness and smoothness of operation. Check for bent tie rods or tie rod ends. Check tie rod boots for damage. If any components are found to be unsatisfactory, they should be replaced.
Fig. 3 Applying grease to steering gear housing. Manual rack & pinion steering gear:
ASSEMBLE
1. Apply lithium grease to rack, pinion, oil seal lips, support yoke and housing areas indicated in, Fig. 3. Also pack upper and lower pinion bearings with lithium grease.
2. Lubricate rack support bushing with lithium grease, position bushing to steering gear housing and push in until locking tabs engage slots in housing.
Fig. 1 Exploded view of manual rack & pinion steering gear:
3. Install support bushings and brackets onto steering gear housing, Fig. 1.
4. Install lower pinion bearing using a suitable tool, if removed.
Fig. 4 Installing rack into steering gear housing. Manual rack & pinion steering gear:
5. Slide rack into steering gear housing as far as possible, Fig. 4.
Fig. 5 Positioning rack & pinion. Manual rack 7 pinion steering gear:
Fig. 6 Torquing adjusting bolt. Manual rack & pinion steering gear:
6. Position rock so that it protrudes 2.68 inch from left hand side of steering gear housing, then install pinion so that the notch on the pinion shaft is at a 30 degree angle from center line of steering gear housing, Fig. 5.
7. Install pinion snap ring and oil seal spacer.
8. Wrap pinion shaft splines with electrical tape, then apply grease to tape and install seal using tool No. T87C-3504-C or equivalent.
9. Position rack in a soft jawed vise, the install replacement tab washers and tie rods. Torque tie rod to rack ball unit to 58 to 72 ft. lbs., then using a suitable punch, stake washer tabs to rack at two locations.
10. Slide boots over tie rods and position on steering gear housing, then install retaining wires.
11. Install support yoke, spacer and spring into steering gear housing.
12. Apply sealer to adjusting cover threads, then install adjusting cover, adjusting bolt and locknut. Torque adjusting cover to 29 to 43 ft. lbs.
13. Torque adjusting bolt to 8.7 inch lbs., then loosen bolt 10 to 40 degrees, Fig. 6.
14. With rack centered in steering gear housing, use and inch lb. torque wrench to measure pinion rotating torque. Do not turn pinion more than 90 degrees past the center position. Pinion rotating torque should be 7.8 to 11.28 inch lbs. If rack needs to be checked beyond the 90 degrees from center point, pinion rotating torque should nut exceed 13 inch lbs. Pinion rotating torque is adjusted by loosening or tightening the adjusting bolt.
15. After completing adjustment, torque adjusting bolt locknut to 7.2 to 10.8 ft. lbs.
16. Remove tape from pinion shaft and apply lithium grease to area around seal.
17. Install tie rod ends and jam nuts, aligning marks made during disassembly.