Power Steering Gear Box: Reassembly
- Lubricate bearing surface of side cover and install needle roller bearings. Insert adjusting bolt and plate into the" T" slot on top of cross shaft, and set play with adjusting shims. Cross shaft play is 0-.002" (0-0.5 mm). When installing adjusting shims place chamfered edge of adjusting plate to contact surface of cross shaft. Install side cover "O" ring. See Fig 1 .
- Align cross shaft with side cover and tighten with adjusting bolt. Tighten lock nut temporarily. Install ball bearing and oil seal in top cover. Gently insert "O" ring and seal ring into seal housing and install housing in gear box with "O" ring side toward the main shaft. Install oil seal back-up ring and snap ring in gear box.
- Install "O" ring and seal ring to input worm shaft. Install thrust plates and needle bearings in input worm unit.NOTE: Install top cover side thrust plate with smaller outside diameter first.
- Install "O" ring and seal ring into valve housing. Fit 2 "O" rings in groove at end of valve housing. Install input worm unit in valve housing. Fit top cover "O" ring, and install top cover to valve housing. Tighten nut. Measure input worm unit preload. Torque should be 2.2-5.8 INCH lbs. (2.5-6.6 cmkg). Adjust, if necessary, by loosening valve housing nut and retightening.
- Fit "O" ring and seal ring to rack-piston. Insert rack-piston into worm unit and turn worm unit to align ball sliding surfaces. Install 19 balls, into small gear box or 20 balls into large gear box, into rack-piston through the 2 openings.
NOTE: Do not move rack-piston when installing balls, as balls may fall into wrong groove.
- After installing specified number of balls, measure distance from rack-piston to the ball. If distance is more than 0.5" (13 mm) on small gear box or 0.08" (2 mm) on large gear box, this indicates a ball has fallen into wrong groove. Remove balls then reinstall them, being sure all balls are installed correctly. Insert remaining 7 balls (on small gear box) or 6 balls (on large gear box) and install circulator holder.
- Install rack-piston of the ball screw unit assembly to gear box and tighten. Install seal ring of rack-piston and place rack-piston in neutral (center) position. Install cross shaft and side cover and tighten.
- Measure starting torque of input shaft and adjust to 4.3-7.8 INCH lbs. (5.1-9.2 cmkg) on large gear box or to 3.5-7.0 INCH lbs. (4.1-8.2 cmkg) on small gear box. Tighten valve housing nut. Measure preload after tightening. Connect cross shaft with pitman arm.