Disassembly and Assembly

DISASSEMBLY

Steering Gear:

1. Remove steering gear from vehicle, then secure gear in a soft-jawed vise.
2. Remove four fluid lines and fluid line clamp, then the mounting brackets and bushings. Before removing fluid lines, mark locations for proper assembly.
3. Mark tie rod ends with alignment marks for reassembly, then remove tie rod ends and jam nuts.
4. Remove dust boots, then the inner tie rods.
5. Remove adjusting cover locknut using yoke locknut wrench T88C-3504-KH, then the adjusting cover using yoke plug adapter T81P-3504-U.
6. Remove spring and pressure pad, then the pinion snap ring.
7. Drill away staked areas of housing cover, then remove housing cover.
8. Remove lower bearing locknut, then the pinion shaft, oil seal and upper bearing using valve body puller bridge T86P-3504-D and valve body puller T78P-3504-B.
9. Remove four O-rings from pinion shaft, then drill away staked areas of end cap using stake remover fixture T92C-3504-CH.
10. Remove end cap using outer box torque wrench T88C-3504-NH, secure end cap in a vise, then remove end cap bushing using blind hole puller set D80L-100-A.
11. Remove rack and rack outer oil seal from right side of housing using impact slide hammer T50T-100-A, rack puller adapter T88C-3504-OH and adjustable rack seal protector D83P-3504-A.
12. Remove rack internal oil seal using rack oil seal remover T78P-3504-J and impact slide hammer T50T-100-A.
13. Remove spacer, then the lower pinion shaft bearing using pulley attachment T58P-101-B.
14. Remove lower pinion shaft and pinion shaft collar using handle T87P-3504-D and pinion oil seal and spacer remover/replacer T92C-3504-BH.
15. Remove rack O-ring and rack seal using O-ring tool T71P-19703-C.

INSPECTION
1. Pinion shaft is not serviceable. Inspect pinion shaft for cracking, damage, and wear. If any of these conditions exist, steering gear must be replaced.
2. Inspect end cap and replace if threads are damaged.
3. Rack is not serviceable. Inspect rack for cracking, damage, or wear. If any of these conditions exist, steering gear must be replaced.
4. Rack internal oil seal is not serviceable. If evidence of leaking is found, steering gear must be replaced.

ASSEMBLY
1. Install rack O-ring and rack seal on rack using teflon ring expander T88C-3504-EH.
2. Install pinion shaft collar using handle T87P-3504-D and pinion oil seal and spacer remover/replacer T92C-3504-BH.
3. Install lower pinion shaft oil seal using drive handle T80T-4000-W and pinion seal replacer T84P-3504-F.
4. Install lower pinion shaft bearing using drive handle and pinion bearing installer T90P-3504-OH.
5. Install rack internal oil seal and spacer using seal installer T88C-3504-DH.
6. Install rack using teflon ring sizing/installer T88C-3504-FH and adjustable rack oil seal protector D83P-3504-A.
7. Seat rack outer oil seal using outer rack seal replacer T88C-3504-GH.
8. Install bushing in end cap using a press and flat plates.
9. Install end cap using outer box torque wrench T88C-3504-NH, then stake rack housing at two points approximately 0.06 inch from end of housing with a punch and hammer. Stake housing at point 90 degrees from part cut away with drill during disassembly.
10. Install mandrel T81P-3504-M1 over top of pinion shaft, then lubricate mandrel with power steering fluid.
11. Slide one O-ring over top of mandrel, then slide pusher T81P-3504-M2 over mandrel and push down rapidly forcing O-ring down ramp and into fourth groove of pinion shaft.
12. Install one spacer T81P-3504-M4 over top of pinion shaft, then the mandrel over spacer.
13. Slide one O-ring over top of mandrel, then slide pusher over mandrel and push down rapidly forcing O-ring down ramp and into third groove of pinion shaft.
14. Install two spacers over top of pinion shaft, then the mandrel over spacer.
15. Slide one O-ring over top of mandrel, then slide pusher over mandrel and push down rapidly forcing O-ring down ramp and into second groove of pinion shaft.
16. Install two spacers over top of pinion shaft, then the mandrel over spacer.
17. Slide one O-ring over top of mandrel, then slide pusher over mandrel and push down rapidly forcing O-ring down ramp and into first groove of pinion shaft.
18. Install pinion shaft into housing using ring sizer T81P-3504-M3. Rotate pinion shaft slightly from side to side to mesh pinion with rack.
19. Install upper pinion shaft bearing and oil seal using pinion seal/torque adapter T88C-3504-BH.
20. Install new pinion snap ring. Ensure that snap ring is seated in ring groove of housing.
21. Install lower bearing locknut and torque to 29-36 ft lb.
22. Apply thread locking compound to housing cover threads, then install housing cover and torque to 18-25 ft lb. Stake housing cover with a punch and hammer.
23. Install pressure pad and spring.
24. Apply thread locking compound to exposed threads of adjusting cover, install adjusting cover and torque to 87 in lb using yoke plug adapter T81P-3504-U, then loosen it. Torque cover again to 39-48 in lb, then loosen 45 degrees.
25. Install adjusting cover locknut and torque to 36-43 ft lb using yoke locknut wrench T88C-3504-KH while holding adjusting cover. Do not allow adjusting cover to turn.
26. Install inner tie rods, then the dust boots.
27. Install tie rod ends and jam nuts, then the mounting brackets and bushings.
28. Install fluid lines and fluid line clamp, then the steering gear in vehicle.