Input Shaft and Valve Assembly

Tools Required:

• Impact Slide Hammer T50T-100-A
• Bench Mounted Holding Fixture T57L-500-B
• Puller Attachment T58L-101-B
• Pinion Shaft Torque Adapter T74P-3504-R
• Mandrel T75L-3517-A1
• Pusher T75L-3517-A2
• Spacer T75L-3517-A3
• Sizing Tube T75L-3517-A4
• Valve Body Puller T78P-3504-B
• Valve Body Insert Tool T78D-3504-C
• Upper Pinion Bearing Seal Replacer T78P-3504-D
• Lower Pinion Seal Remover T78P-3504-E2
• Lower Pinion Bearing Replacer T78P-3504-G
• Dust Seal Installer T85T-3504-CH1
• Seal Installer T85T-3504-CH2
• Retaining Ring Pliers D79L-7000-A
• Lower Pinion Seal Remover D82P-3504-E1

Disassembly

1. Thoroughly clean the areas of the input shaft valve housing, yoke locknut and plug, and pinion bearing plug.

2. Mount gear in the Bench Mounted Holding Fixture T57L-500-B.

3. Do not remove the external pressure lines (RH and LH turn lines), unless they are leaking or damaged. If these lines are removed, new Teflon seals must be installed.
   
   
   
   

4. Loosen the yoke plug locknut and the yoke plug to relieve the preload on the rack.

5. Remove the pinion bearing plug.

    CAUTION: Do not allow rack to reach full travel when loosening or tightening the locknut as damage to rack teeth may result.

6. Install Pinion Shaft Torque Adapter T74P-3504-R on the input shaft. Hold the input shaft, and remove the pinion bearing locknut with an 11/16-inch socket. Discard the locknut.
   
   
   
   

    CAUTION: Use care not to damage any of the valve housing surfaces.

7. Pry the input shaft dust seal out of the valve housing with a small, sharp chisel.
   
   
   
   

8. Remove retaining snap ring, located beneath the dust seal, from the valve housing using Retaining Ring Pliers D79L-7000-A or equivalent.
   
   
   
   

9. Attach input shaft and Valve Body Puller T78P-3504-B to input shaft. Turn nut to remove valve. Input shaft seal and bearing will come out with the valve body.
   
   
   
   

10. To remove the lower pinion shaft seal, insert Part of Lower Pinion Seal Remover T78P-3504-E2 until it bottoms along with the spacer collet (Part of Lower Pinion Seal Remover D82P-3504-E1 or equivalent). Activate the expander with a pair of wrenches by holding the large nut and turning the small nut until expander fully tightens. Pull tool and seal with Impact Slide Hammer T50T-100-A.
    
    
    
    
    
    
    
    

11. Remove the pinion bearing from the gear housing with Impact Slide Hammer T50T-100-A and Puller Attachment T58L-101-B.
    
    
    
    

     CAUTION: Use care not to scratch the valve sleeve as it may leak internally.

12. The only serviceable components of the input shaft and valve assembly are the four plastic O-rings. Remove the O-rings by pushing the rings to one side, inserting a small pointed pocket knife under each ring, and cutting it off.
    
    
    
    

Assembly

1. Install steering gear pinion bearing in gear housing using Lower Pinion Bearing Replacer T78P-3504-G. Seat the bearing against the shoulder in the bore. Support valve housing with a wood block when seating pinion bearing.
   
   
   
   
   
   
   
   

2. Apply Steering Gear Grease C3AZ-19578-A (ESW-M1C87-A) or equivalent to pinion oil seal, and place it on Lower Pinion Seal Replacer T78P-3504-F with seal lip toward tool. Support the pinion housing on a flat, clean surface. Install seal in the valve bore, seating it against shoulder.
   
   
   
   

3. Mount the pinion end of the valve assembly into a soft-jawed vise.

4. Lubricate Mandrel T75L-3517-A1 with power steering fluid and install over the valve assembly. Slide one valve sleeve ring over the tool.
   
   
   
   

5. Slide Pusher T75L-3517-A2 over the mandrel. Rapidly push down on the pusher tool, forcing the ring down the ramp into the fourth groove of the valve sleeve. Repeat this Step three more times, and each time, add one of the spacers, Spacer T75L-3517-A3 under the mandrel. By adding the spacer each time, the mandrel will line up with the next groove of the valve sleeve.

6. After installing the four valve sleeve rings, apply a light coat of Steering Gear Grease C3AZ-19578-A (ESA-M1C175-A) or equivalent to the sleeve and rings.

7. Install one spacer over the input shaft as a pilot for installing the sizing tube. Slowly install Sizing Tube T75L-3517-A4 over the sleeve valve end of the input shaft onto the valve sleeve rings. Make sure that the rings are not being bent over as the tube is slid over them.
   
   
   
   
   
   
   
   
   
   
   
   

   NOTE: If only the valve was serviced and the rack was not moved while the valve was out, Step 9 may be omitted.

8. Remove the sizing tube, and check the condition of the rings. Make sure that the rings turn freely in the grooves.

9. If rack was removed and marked with paint, position rack so that paint mark is centered in valve bore. If rack was not removed, position rack in the housing, so that the RH end protrudes 6mm (1/4 inch) more than the LH end.

10. Insert Valve Body Insert Tool T78P-3504-C into valve housing. Line up the D-flat on the input shaft 180 degrees from the yoke plug hole center, and insert valve assembly into the bore. The D-flat must point straight down when the gear is installed in the vehicle with the gear on center (straight-ahead position). Rotate input shaft slightly side-to-side, if necessary, to mesh the pinion to the rack teeth. Push valve assembly in by hand until seated properly.
    
    
    
    

11. Using Pinion Shaft Torque Adapter T74P-3504-R to turn input shaft, check if pinion is centered by counting the number of turns from center to each stop (approximately 1-1/2 turns for the variable ratio gear or 1-1/4 turns for the constant ratio). If the number of turns is unequal, pull the valve assembly out far enough to free the pinion teeth. Rotate input shaft 60 degrees (one tooth) in direction that required less turns. Insert valve assembly, and check if on center. Repeat procedure if necessary.

12. Install nut on pinion end of valve assembly. Holding the input shaft with Pinion Shaft Torque Adapter T74P-3504-R, tighten the nut to 41-54 Nm (30-40 lb-ft). The rack must be away from the stops during this operation.

13. Install bearing in valve bore and seat with Upper Pinion Bearing Seal Replacer T78P-3504-D.
    
    
    
    
    
    
    
    

14. Apply a film of Steering Gear Grease C3AZ-19578-A (ESW-M1C89-A) or equivalent to the input shaft seal, and install with lip toward valve. Seat seal with Upper Pinion Bearing Seal Replacer T78P-3504-D.
    
    
    
    

15. Install retaining snap ring in valve bore.

16. Coat the input shaft in the dust seal contact area with Multi-Purpose Grease D0AZ-19584-AA (ESR-M1C159-A) or equivalent.

17. Install Input Shaft Dust Seal Installer T85T-3504-CH1 over the input shaft.
    
    
    
    

18. Install the input shaft dust seal and drive into position using Seal Installer T85T-3504-CH2.
    
    
    
    

19. Remove the Dust Seal Installer from the seal and input shaft. This allows trapped air to be released.
    
    
    
    

20. Install umbrella seal. Make sure seal is engaged in groove on input shaft.
    
    
    
    

21. Install steering gear housing cap, and tighten to 54-68 Nm (40-50 lb-ft).
    
    
    
    

    NOTE: Yoke must seat against the rack with finger pressure. If yoke hangs up, check for burrs in yoke housing.

22. Fill yoke housing with 57 grams (2 oz) of specified gear lubricant. Install plastic yoke.
    
    
    
    

23. Install yoke thrust spring.
    
    
    
    

24. Install yoke plug.

25. Install yoke plug locknut. Prior to tightening the locknut, set the rack yoke plug preload as outlined.

26. If the external pressure lines were removed, new Teflon seals must be installed. Slide back the tube nut and cut old seal off. Remove any portion of the old seal left in the port. Lubricate the new Teflon seal with power steering fluid, and install by stretching it over the tube flange.