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Steering Gear: Reassembly

  1. Drive check valve into housing using a 3/8" (9.5 mm) diameter tubing, 4" (102 mm) long. Coat pitman shaft double-lip seal and washer with grease. Using Pitman Shaft Bearing Remover/Installer (J-6278), install needle bearing.
  2. Using Pitman Shaft Oil Seal Installer (J-6219), install single-lip seal, then washer. Install double-lip seal and back-up washer. Using Internal Snap Ring Pliers (J-4245), install retaining ring. Install worm shaft "O" ring seal and Teflon ring. Fully seat worm shaft to rack piston. Align worm shaft groove with rack piston ball return guide hole.
    NOTE: Black balls are smaller than Silver balls. Black and Silver balls must be installed alternately into rack piston and ball guide to maintain preload.
  3. Lubricate balls with power steering fluid. Insert balls into ball return guide holes while turning worm shaft counterclockwise. Install remaining balls into ball guide. Apply light grease to each end of ball guide to retain balls. Install ball guide and guide clamp. Tighten ball guide clamp screws.
  4. Insert Rack Piston Arbor (J-21552) into rack piston bore while turning worm shaft counterclockwise. Install races and thrust bearing onto worm shaft. Insert worm shaft into housing.
  5. Lubricate valve spool and "O" ring seal with power steering fluid. Assemble valve spool "O" ring seal and valve spool. Assemble valve spool and valve body by pushing and rotating until hole in valve spool for stub shaft pin is accessible from opposite end of valve body.
  6. Assemble stub shaft and valve spool. Insert retaining pin. Ensure notch in stub shaft cap fully engages valve body pin and seats against valve body shoulder.
  7. Assemble "O" ring seals, Teflon rings and valve body. Assemble stub shaft, valve assembly and worm shaft. Ensure pin on stub shaft aligns with slot in valve assembly. Install stub shaft and worm shaft into housing. Hold rack piston arbor tightly against worm shaft while turning stub shaft clockwise until rack piston seats on worm shaft. Install rack piston plug. Use Rack Piston Teflon Ring Compressor (J-8947) to compress seals.
  8. Place stub shaft adjuster plug on suitable support with outside of plug facing up. Using Adjuster Plug Bearing Remover/Installer (J-6221), assemble stub shaft needle bearing and adjuster plug. Ensure identification mark on needle bearing faces remover/installer during installation. Using adjuster plug bearing remover/installer, assemble lip seal and dust seal. Install retaining ring.
  9. Assemble "O" ring seal, large bearing race, thrust bearing, small bearing race, bearing spacer, thrust bearing retainer and adjuster plug. Install adjuster plug assembly into housing using Spanner Wrench (J-7624). DO NOT cut seals when installing adjuster plug.
  10. Install housing end plug "O" ring seal, end plug and retaining ring into housing. Ensure open end of retaining ring is about one inch (25 mm) from access hole in housing.
  11. Screw pitman shaft into side cover until it is fully seated. Install pitman shaft lock nut. Place gasket on side cover, bending gasket tabs around edge of side cover. Install pitman shaft and side cover into housing. Install and tighten cover bolts to specification. See TORQUE SPECIFICATIONS  .
  12. Using Pitman Shaft Oil Seal Installer (J-6219), install pitman shaft seals, washers and retaining ring. Adjust steering gear. See WORM BEARING PRELOAD and PITMAN SHAFT OVER-CENTER TURNING TORQUE  .
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