With Variable Assist

Fig. 22 Removing Adjust Cover Locknut:

DISASSEMBLE

1. Mount steering gear in a suitable vise equipped with soft jaws.
2. Remove external hydraulic lines connecting valve body to steering gear housing.
3. Remove solenoid valve from left mounting bracket.
4. Remove mounting brackets and rubber bushings from steering gear.
5. Scribe alignment marks on tie rods and tie rod ends, then remove tie rod ends.
6. Using a suitable chisel, uncrimp tie rod assembly lockwasher.
7. Using a 30mm crowfoot wrench, remove tie rod from steering gear.
8. Remove adjust cover locknut, Fig. 22.
9. Using yoke torque gauge tool No. T88C-3504-AH, remove adjust cover, spring and pressure pad.
10. Using outer torque box adapter tool No. T88C-3504-CH, remove outer box assembly.
11. Using a screwdriver, remove pinion shaft oil seal.

INSPECTION

1. Check bearings for looseness, abnormal noise or poor operation. If pinion bearing requires replacement, replace entire steering gear assembly.
2. Check for looseness or lack of smoothness in tie rod ball housings.
3. Check for bent tie rods or tie rod ends.
4. Check outer bulkhead bushing for wear.
5. Check tie rod boot for cracking, damage or deterioration.

Fig. 23 Staking The Bulkhead:

Fig. 24 Installing Pressure Pad & Spring:

ASSEMBLE

1. Lubricate outer box assembly with automatic transmission fluid.
2. Using outer torque adapter tool No. T88C-3504-CH, install outer box assembly.
3. Stake the outer box assembly to the rack housing using a punch, Fig. 23.
4. Apply a thin coat of grease to lips of pinion seal, then install pinion seal using seal installer tool No. T88C-3504-BH.
5. Install pressure pad and spring into gear housing, Fig 24.
6. Apply thread sealer to adjust cover.
7. Using torque gauge tool No. T88C-3504-AH, install adjust cover and torque to 29-36 inch lbs.
8. Loosen adjust cover 35°.
9. Using pinion adapter tool No. T88C-3504-BH, measure pinion torque, torque should be 88.5-123.9 inch lbs.
10. Install adjust cover locknut and torque to 28.9-36.2 ft. lbs.
11. Install washer and tie rod. Torque tie rod to 43.4-57.9 ft .lbs.
12. Bend washer tang to lock tie rod in place.
13. Slide tie rod boot over tie rod and position it on steering gear.
14. Wrap a new piece of mechanics wire around the boot twice, then around a Phillips screwdriver. Twist the wire four or five times with the screwdriver. Ensure boot is not dented or twisted.
15. Install outer boot clamp.
16. Install tie rod ends, ensuring index marks are aligned.
17. Install rubber mounting bushings and mounting brackets.
18. Install solenoid valve on mounting bracket.
19. Install external hydraulic lines connecting valve body to gear. Use new copper washers at each banjo fitting.