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Diagnosis and repair



Take the following precautions when servicing the steering gear:
1.Use a clean workbench and tools.
2.Thoroughly clean the exterior of the gear with solvent and drain off excess hydraulic fluid if necessary.
3.Handle all parts carefully to avoid nicks burrs scratches and dirt.
4.Do not use solvent on seals.

Steering Gear

Disassembly

1.Hold the steering gear upside down over a drain pan and cycle the input shaft several times to drain the fluid from the gear.


{tag}1250020219@


2.Secure the gear in a soft-jawed vise.
3.Turn the input shaft to either stop then turn it back two turns to center the gear.

NOTE: The indexing flat on the input shaft should be facing downward.

4.Remove the sector shaft cover attaching bolts.
5.Tap the lower end of the sector shaft with a soft hammer to loosen it and lift the cover and shaft from the housing as an assembly. Discard the O-ring.

NOTE: The following step is required only when it is necessary to remove sector shaft from the sector assembly.

6.Remove the nut from the sector shaft adjusting screw. Turn the sector shaft cover counterclockwise and remove it from the sector shaft adjuster screw.
7.Remove the valve housing attaching bolts and identification tag. Lift the valve housing off the steering gear housing. Remove the valve housing piston assembly and control valve gasket. Discard the gasket.

NOTE: If valve housing or the valve sleeve seals are to be replaced, proceed to Step 11. If sector shaft seals are to be replaced go to steering gear housing section. Balls need to be removed if valve sleeve rings are to be replaced.

8.With the piston held so the ball guide faces up remove the ball guide clamp screws and ball guide clamp.


{tag}1250145985@


9.With a finger over the opening in the ball guide turn the piston so the ball guide faces down over a clean container. Let the guide tubes drop into the container.
10.Rotate the input shaft from stop to stop until all balls fall from the piston into the container. The valve assembly can then be removed from the piston. Inspect the piston bore to make sure all balls have been removed.
11.Install the valve body assembly in the Bench Mounted Holding Fixture T57L-500-B and loosen the Allen head race locknut screw from the valve housing.
12.Remove the worm bearing race locknut using Adjuster and Locknut Wrench T66P-3553-B and Valve Housing to Piston Spacer T66P-3553-C.


{tag}1250267634@


13.Carefully slide the input shaft worm and valve assembly out of the valve housing.

Assembly

1.Mount the valve housing in the Bench Mounted Holding Fixture T57L-500-B with the flanged end up.
2.Apply a light coat of Premium Power Steering Fluid E6AZ-19582-AA (ESW-M2C33-F) or equivalent to the Teflon rings on the valve sleeve.
3.Carefully install the worm shaft and valve in the housing.
4.Install the worm bearing race locknut in the housing and tighten to 75-122 Nm (55-90 ft-lb).
5.Install the Allen head race locknut set screw through the valve housing and tighten to 1.7-2.8 Nm (15-25 in-lb).
6.Place the piston on the bench with the ball guide holes facing up. Insert the worm into the piston so the first groove is in line with the hole nearest the center of the piston.
7.Place the ball guides in the piston. Turning the input shaft counterclockwise place the same balls as removed in Step 9 of Steering Gear Disassembly in the ball guide. During assembly 27 to 29 balls are required. If all the balls have not been inserted upon reaching the left stop rotate the input shaft in one direction then the other while inserting the remaining balls.


{tag}1250444254@

Steering Gear Assembly

8.Secure the guides in the ball nut with the clamp. Tighten screws to 4.8-7.9 Nm (42-70 in-lb).
9.Apply petroleum jelly or equivalent to the Teflon seal on the piston.
10.Place a new control valve O-ring on the valve housing.
11.Slide the piston and valve into the gear housing being careful not to damage the piston ring.
12.Align the oil passage in the valve housing with the passage in the gear housing. Place a new O-ring onto the oil passage hole of the gear housing. Install identification tag onto the housing. Install but do not tighten, the attaching bolts. Identification tag is to be installed under upper right valve housing bolt.
13.Rotate the piston so the teeth are in the same plane as the sector teeth. Tighten the valve housing attaching bolts to 40-60 Nm (30-45 ft-lb).
14.Position the sector shaft cover O-ring in the steering gear housing. Turn the input shaft to center the piston.
15.Apply petroleum jelly or equivalent to the sector shaft journal and position the sector shaft and cover assembly in the gear housing. Install the sector shaft cover attaching bolts. Tighten the bolts to 75-94 Nm (55-70 ft-lb).
16.Attach an inch-pound torque wrench to the input shaft. Adjust meshload to specification. Take the following precautions when servicing the steering gear:
1.Use a clean workbench and tools.
2.Thoroughly clean the exterior of the gear with solvent and drain off excess hydraulic fluid if necessary.
3.Handle all parts carefully to avoid nicks burrs scratches and dirt.
4.Do not use solvent on seals.

Steering Gear

Disassembly

1.Hold the steering gear upside down over a drain pan and cycle the input shaft several times to drain the fluid from the gear.






2.Secure the gear in a soft-jawed vise.
3.Turn the input shaft to either stop then turn it back two turns to center the gear.

NOTE: The indexing flat on the input shaft should be facing downward.

4.Remove the sector shaft cover attaching bolts.
5.Tap the lower end of the sector shaft with a soft hammer to loosen it and lift the cover and shaft from the housing as an assembly. Discard the O-ring.

NOTE: The following step is required only when it is necessary to remove sector shaft from the sector assembly.

6.Remove the nut from the sector shaft adjusting screw. Turn the sector shaft cover counterclockwise and remove it from the sector shaft adjuster screw.
7.Remove the valve housing attaching bolts and identification tag. Lift the valve housing off the steering gear housing. Remove the valve housing piston assembly and control valve gasket. Discard the gasket.

NOTE: If valve housing or the valve sleeve seals are to be replaced, proceed to Step 11. If sector shaft seals are to be replaced go to steering gear housing section. Balls need to be removed if valve sleeve rings are to be replaced.

8.With the piston held so the ball guide faces up remove the ball guide clamp screws and ball guide clamp.


{tag}1250145985@


9.With a finger over the opening in the ball guide turn the piston so the ball guide faces down over a clean container. Let the guide tubes drop into the container.
10.Rotate the input shaft from stop to stop until all balls fall from the piston into the container. The valve assembly can then be removed from the piston. Inspect the piston bore to make sure all balls have been removed.
11.Install the valve body assembly in the Bench Mounted Holding Fixture T57L-500-B and loosen the Allen head race locknut screw from the valve housing.
12.Remove the worm bearing race locknut using Adjuster and Locknut Wrench T66P-3553-B and Valve Housing to Piston Spacer T66P-3553-C.


{tag}1250267634@


13.Carefully slide the input shaft worm and valve assembly out of the valve housing.

Assembly

1.Mount the valve housing in the Bench Mounted Holding Fixture T57L-500-B with the flanged end up.
2.Apply a light coat of Premium Power Steering Fluid E6AZ-19582-AA (ESW-M2C33-F) or equivalent to the Teflon rings on the valve sleeve.
3.Carefully install the worm shaft and valve in the housing.
4.Install the worm bearing race locknut in the housing and tighten to 75-122 Nm (55-90 ft-lb).
5.Install the Allen head race locknut set screw through the valve housing and tighten to 1.7-2.8 Nm (15-25 in-lb).
6.Place the piston on the bench with the ball guide holes facing up. Insert the worm into the piston so the first groove is in line with the hole nearest the center of the piston.
7.Place the ball guides in the piston. Turning the input shaft counterclockwise place the same balls as removed in Step 9 of Steering Gear Disassembly in the ball guide. During assembly 27 to 29 balls are required. If all the balls have not been inserted upon reaching the left stop rotate the input shaft in one direction then the other while inserting the remaining balls.


{tag}1250444254@

Steering Gear Assembly

8.Secure the guides in the ball nut with the clamp. Tighten screws to 4.8-7.9 Nm (42-70 in-lb).
9.Apply petroleum jelly or equivalent to the Teflon seal on the piston.
10.Place a new control valve O-ring on the valve housing.
11.Slide the piston and valve into the gear housing being careful not to damage the piston ring.
12.Align the oil passage in the valve housing with the passage in the gear housing. Place a new O-ring onto the oil passage hole of the gear housing. Install identification tag onto the housing. Install but do not tighten, the attaching bolts. Identification tag is to be installed under upper right valve housing bolt.
13.Rotate the piston so the teeth are in the same plane as the sector teeth. Tighten the valve housing attaching bolts to 40-60 Nm (30-45 ft-lb).
14.Position the sector shaft cover O-ring in the steering gear housing. Turn the input shaft to center the piston.
15.Apply petroleum jelly or equivalent to the sector shaft journal and position the sector shaft and cover assembly in the gear housing. Install the sector shaft cover attaching bolts. Tighten the bolts to 75-94 Nm (55-70 ft-lb).
16.Attach an inch-pound torque wrench to the input shaft. Adjust meshload to specification. Take the following precautions when servicing the steering gear:
1.Use a clean workbench and tools.
2.Thoroughly clean the exterior of the gear with solvent and drain off excess hydraulic fluid if necessary.
3.Handle all parts carefully to avoid nicks burrs scratches and dirt.
4.Do not use solvent on seals.

Steering Gear

Disassembly

1.Hold the steering gear upside down over a drain pan and cycle the input shaft several times to drain the fluid from the gear.


{tag}1250020219@


2.Secure the gear in a soft-jawed vise.
3.Turn the input shaft to either stop then turn it back two turns to center the gear.

NOTE: The indexing flat on the input shaft should be facing downward.

4.Remove the sector shaft cover attaching bolts.
5.Tap the lower end of the sector shaft with a soft hammer to loosen it and lift the cover and shaft from the housing as an assembly. Discard the O-ring.

NOTE: The following step is required only when it is necessary to remove sector shaft from the sector assembly.

6.Remove the nut from the sector shaft adjusting screw. Turn the sector shaft cover counterclockwise and remove it from the sector shaft adjuster screw.
7.Remove the valve housing attaching bolts and identification tag. Lift the valve housing off the steering gear housing. Remove the valve housing piston assembly and control valve gasket. Discard the gasket.

NOTE: If valve housing or the valve sleeve seals are to be replaced, proceed to Step 11. If sector shaft seals are to be replaced go to steering gear housing section. Balls need to be removed if valve sleeve rings are to be replaced.

8.With the piston held so the ball guide faces up remove the ball guide clamp screws and ball guide clamp.






9.With a finger over the opening in the ball guide turn the piston so the ball guide faces down over a clean container. Let the guide tubes drop into the container.
10.Rotate the input shaft from stop to stop until all balls fall from the piston into the container. The valve assembly can then be removed from the piston. Inspect the piston bore to make sure all balls have been removed.
11.Install the valve body assembly in the Bench Mounted Holding Fixture T57L-500-B and loosen the Allen head race locknut screw from the valve housing.
12.Remove the worm bearing race locknut using Adjuster and Locknut Wrench T66P-3553-B and Valve Housing to Piston Spacer T66P-3553-C.


{tag}1250267634@


13.Carefully slide the input shaft worm and valve assembly out of the valve housing.

Assembly

1.Mount the valve housing in the Bench Mounted Holding Fixture T57L-500-B with the flanged end up.
2.Apply a light coat of Premium Power Steering Fluid E6AZ-19582-AA (ESW-M2C33-F) or equivalent to the Teflon rings on the valve sleeve.
3.Carefully install the worm shaft and valve in the housing.
4.Install the worm bearing race locknut in the housing and tighten to 75-122 Nm (55-90 ft-lb).
5.Install the Allen head race locknut set screw through the valve housing and tighten to 1.7-2.8 Nm (15-25 in-lb).
6.Place the piston on the bench with the ball guide holes facing up. Insert the worm into the piston so the first groove is in line with the hole nearest the center of the piston.
7.Place the ball guides in the piston. Turning the input shaft counterclockwise place the same balls as removed in Step 9 of Steering Gear Disassembly in the ball guide. During assembly 27 to 29 balls are required. If all the balls have not been inserted upon reaching the left stop rotate the input shaft in one direction then the other while inserting the remaining balls.


{tag}1250444254@

Steering Gear Assembly

8.Secure the guides in the ball nut with the clamp. Tighten screws to 4.8-7.9 Nm (42-70 in-lb).
9.Apply petroleum jelly or equivalent to the Teflon seal on the piston.
10.Place a new control valve O-ring on the valve housing.
11.Slide the piston and valve into the gear housing being careful not to damage the piston ring.
12.Align the oil passage in the valve housing with the passage in the gear housing. Place a new O-ring onto the oil passage hole of the gear housing. Install identification tag onto the housing. Install but do not tighten, the attaching bolts. Identification tag is to be installed under upper right valve housing bolt.
13.Rotate the piston so the teeth are in the same plane as the sector teeth. Tighten the valve housing attaching bolts to 40-60 Nm (30-45 ft-lb).
14.Position the sector shaft cover O-ring in the steering gear housing. Turn the input shaft to center the piston.
15.Apply petroleum jelly or equivalent to the sector shaft journal and position the sector shaft and cover assembly in the gear housing. Install the sector shaft cover attaching bolts. Tighten the bolts to 75-94 Nm (55-70 ft-lb).
16.Attach an inch-pound torque wrench to the input shaft. Adjust meshload to specification. Take the following precautions when servicing the steering gear:
1.Use a clean workbench and tools.
2.Thoroughly clean the exterior of the gear with solvent and drain off excess hydraulic fluid if necessary.
3.Handle all parts carefully to avoid nicks burrs scratches and dirt.
4.Do not use solvent on seals.

Steering Gear

Disassembly

1.Hold the steering gear upside down over a drain pan and cycle the input shaft several times to drain the fluid from the gear.






2.Secure the gear in a soft-jawed vise.
3.Turn the input shaft to either stop then turn it back two turns to center the gear.

NOTE: The indexing flat on the input shaft should be facing downward.

4.Remove the sector shaft cover attaching bolts.
5.Tap the lower end of the sector shaft with a soft hammer to loosen it and lift the cover and shaft from the housing as an assembly. Discard the O-ring.

NOTE: The following step is required only when it is necessary to remove sector shaft from the sector assembly.

6.Remove the nut from the sector shaft adjusting screw. Turn the sector shaft cover counterclockwise and remove it from the sector shaft adjuster screw.
7.Remove the valve housing attaching bolts and identification tag. Lift the valve housing off the steering gear housing. Remove the valve housing piston assembly and control valve gasket. Discard the gasket.

NOTE: If valve housing or the valve sleeve seals are to be replaced, proceed to Step 11. If sector shaft seals are to be replaced go to steering gear housing section. Balls need to be removed if valve sleeve rings are to be replaced.

8.With the piston held so the ball guide faces up remove the ball guide clamp screws and ball guide clamp.






9.With a finger over the opening in the ball guide turn the piston so the ball guide faces down over a clean container. Let the guide tubes drop into the container.
10.Rotate the input shaft from stop to stop until all balls fall from the piston into the container. The valve assembly can then be removed from the piston. Inspect the piston bore to make sure all balls have been removed.
11.Install the valve body assembly in the Bench Mounted Holding Fixture T57L-500-B and loosen the Allen head race locknut screw from the valve housing.
12.Remove the worm bearing race locknut using Adjuster and Locknut Wrench T66P-3553-B and Valve Housing to Piston Spacer T66P-3553-C.


{tag}1250267634@


13.Carefully slide the input shaft worm and valve assembly out of the valve housing.

Assembly

1.Mount the valve housing in the Bench Mounted Holding Fixture T57L-500-B with the flanged end up.
2.Apply a light coat of Premium Power Steering Fluid E6AZ-19582-AA (ESW-M2C33-F) or equivalent to the Teflon rings on the valve sleeve.
3.Carefully install the worm shaft and valve in the housing.
4.Install the worm bearing race locknut in the housing and tighten to 75-122 Nm (55-90 ft-lb).
5.Install the Allen head race locknut set screw through the valve housing and tighten to 1.7-2.8 Nm (15-25 in-lb).
6.Place the piston on the bench with the ball guide holes facing up. Insert the worm into the piston so the first groove is in line with the hole nearest the center of the piston.
7.Place the ball guides in the piston. Turning the input shaft counterclockwise place the same balls as removed in Step 9 of Steering Gear Disassembly in the ball guide. During assembly 27 to 29 balls are required. If all the balls have not been inserted upon reaching the left stop rotate the input shaft in one direction then the other while inserting the remaining balls.


{tag}1250444254@

Steering Gear Assembly

8.Secure the guides in the ball nut with the clamp. Tighten screws to 4.8-7.9 Nm (42-70 in-lb).
9.Apply petroleum jelly or equivalent to the Teflon seal on the piston.
10.Place a new control valve O-ring on the valve housing.
11.Slide the piston and valve into the gear housing being careful not to damage the piston ring.
12.Align the oil passage in the valve housing with the passage in the gear housing. Place a new O-ring onto the oil passage hole of the gear housing. Install identification tag onto the housing. Install but do not tighten, the attaching bolts. Identification tag is to be installed under upper right valve housing bolt.
13.Rotate the piston so the teeth are in the same plane as the sector teeth. Tighten the valve housing attaching bolts to 40-60 Nm (30-45 ft-lb).
14.Position the sector shaft cover O-ring in the steering gear housing. Turn the input shaft to center the piston.
15.Apply petroleum jelly or equivalent to the sector shaft journal and position the sector shaft and cover assembly in the gear housing. Install the sector shaft cover attaching bolts. Tighten the bolts to 75-94 Nm (55-70 ft-lb).
16.Attach an inch-pound torque wrench to the input shaft. Adjust meshload to specification. Take the following precautions when servicing the steering gear:
1.Use a clean workbench and tools.
2.Thoroughly clean the exterior of the gear with solvent and drain off excess hydraulic fluid if necessary.
3.Handle all parts carefully to avoid nicks burrs scratches and dirt.
4.Do not use solvent on seals.

Steering Gear

Disassembly

1.Hold the steering gear upside down over a drain pan and cycle the input shaft several times to drain the fluid from the gear.


{tag}1250020219@


2.Secure the gear in a soft-jawed vise.
3.Turn the input shaft to either stop then turn it back two turns to center the gear.

NOTE: The indexing flat on the input shaft should be facing downward.

4.Remove the sector shaft cover attaching bolts.
5.Tap the lower end of the sector shaft with a soft hammer to loosen it and lift the cover and shaft from the housing as an assembly. Discard the O-ring.

NOTE: The following step is required only when it is necessary to remove sector shaft from the sector assembly.

6.Remove the nut from the sector shaft adjusting screw. Turn the sector shaft cover counterclockwise and remove it from the sector shaft adjuster screw.
7.Remove the valve housing attaching bolts and identification tag. Lift the valve housing off the steering gear housing. Remove the valve housing piston assembly and control valve gasket. Discard the gasket.

NOTE: If valve housing or the valve sleeve seals are to be replaced, proceed to Step 11. If sector shaft seals are to be replaced go to steering gear housing section. Balls need to be removed if valve sleeve rings are to be replaced.

8.With the piston held so the ball guide faces up remove the ball guide clamp screws and ball guide clamp.


{tag}1250145985@


9.With a finger over the opening in the ball guide turn the piston so the ball guide faces down over a clean container. Let the guide tubes drop into the container.
10.Rotate the input shaft from stop to stop until all balls fall from the piston into the container. The valve assembly can then be removed from the piston. Inspect the piston bore to make sure all balls have been removed.
11.Install the valve body assembly in the Bench Mounted Holding Fixture T57L-500-B and loosen the Allen head race locknut screw from the valve housing.
12.Remove the worm bearing race locknut using Adjuster and Locknut Wrench T66P-3553-B and Valve Housing to Piston Spacer T66P-3553-C.






13.Carefully slide the input shaft worm and valve assembly out of the valve housing.

Assembly

1.Mount the valve housing in the Bench Mounted Holding Fixture T57L-500-B with the flanged end up.
2.Apply a light coat of Premium Power Steering Fluid E6AZ-19582-AA (ESW-M2C33-F) or equivalent to the Teflon rings on the valve sleeve.
3.Carefully install the worm shaft and valve in the housing.
4.Install the worm bearing race locknut in the housing and tighten to 75-122 Nm (55-90 ft-lb).
5.Install the Allen head race locknut set screw through the valve housing and tighten to 1.7-2.8 Nm (15-25 in-lb).
6.Place the piston on the bench with the ball guide holes facing up. Insert the worm into the piston so the first groove is in line with the hole nearest the center of the piston.
7.Place the ball guides in the piston. Turning the input shaft counterclockwise place the same balls as removed in Step 9 of Steering Gear Disassembly in the ball guide. During assembly 27 to 29 balls are required. If all the balls have not been inserted upon reaching the left stop rotate the input shaft in one direction then the other while inserting the remaining balls.


{tag}1250444254@

Steering Gear Assembly

8.Secure the guides in the ball nut with the clamp. Tighten screws to 4.8-7.9 Nm (42-70 in-lb).
9.Apply petroleum jelly or equivalent to the Teflon seal on the piston.
10.Place a new control valve O-ring on the valve housing.
11.Slide the piston and valve into the gear housing being careful not to damage the piston ring.
12.Align the oil passage in the valve housing with the passage in the gear housing. Place a new O-ring onto the oil passage hole of the gear housing. Install identification tag onto the housing. Install but do not tighten, the attaching bolts. Identification tag is to be installed under upper right valve housing bolt.
13.Rotate the piston so the teeth are in the same plane as the sector teeth. Tighten the valve housing attaching bolts to 40-60 Nm (30-45 ft-lb).
14.Position the sector shaft cover O-ring in the steering gear housing. Turn the input shaft to center the piston.
15.Apply petroleum jelly or equivalent to the sector shaft journal and position the sector shaft and cover assembly in the gear housing. Install the sector shaft cover attaching bolts. Tighten the bolts to 75-94 Nm (55-70 ft-lb).
16.Attach an inch-pound torque wrench to the input shaft. Adjust meshload to specification. Take the following precautions when servicing the steering gear:
1.Use a clean workbench and tools.
2.Thoroughly clean the exterior of the gear with solvent and drain off excess hydraulic fluid if necessary.
3.Handle all parts carefully to avoid nicks burrs scratches and dirt.
4.Do not use solvent on seals.

Steering Gear

Disassembly

1.Hold the steering gear upside down over a drain pan and cycle the input shaft several times to drain the fluid from the gear.






2.Secure the gear in a soft-jawed vise.
3.Turn the input shaft to either stop then turn it back two turns to center the gear.

NOTE: The indexing flat on the input shaft should be facing downward.

4.Remove the sector shaft cover attaching bolts.
5.Tap the lower end of the sector shaft with a soft hammer to loosen it and lift the cover and shaft from the housing as an assembly. Discard the O-ring.

NOTE: The following step is required only when it is necessary to remove sector shaft from the sector assembly.

6.Remove the nut from the sector shaft adjusting screw. Turn the sector shaft cover counterclockwise and remove it from the sector shaft adjuster screw.
7.Remove the valve housing attaching bolts and identification tag. Lift the valve housing off the steering gear housing. Remove the valve housing piston assembly and control valve gasket. Discard the gasket.

NOTE: If valve housing or the valve sleeve seals are to be replaced, proceed to Step 11. If sector shaft seals are to be replaced go to steering gear housing section. Balls need to be removed if valve sleeve rings are to be replaced.

8.With the piston held so the ball guide faces up remove the ball guide clamp screws and ball guide clamp.


{tag}1250145985@


9.With a finger over the opening in the ball guide turn the piston so the ball guide faces down over a clean container. Let the guide tubes drop into the container.
10.Rotate the input shaft from stop to stop until all balls fall from the piston into the container. The valve assembly can then be removed from the piston. Inspect the piston bore to make sure all balls have been removed.
11.Install the valve body assembly in the Bench Mounted Holding Fixture T57L-500-B and loosen the Allen head race locknut screw from the valve housing.
12.Remove the worm bearing race locknut using Adjuster and Locknut Wrench T66P-3553-B and Valve Housing to Piston Spacer T66P-3553-C.






13.Carefully slide the input shaft worm and valve assembly out of the valve housing.

Assembly

1.Mount the valve housing in the Bench Mounted Holding Fixture T57L-500-B with the flanged end up.
2.Apply a light coat of Premium Power Steering Fluid E6AZ-19582-AA (ESW-M2C33-F) or equivalent to the Teflon rings on the valve sleeve.
3.Carefully install the worm shaft and valve in the housing.
4.Install the worm bearing race locknut in the housing and tighten to 75-122 Nm (55-90 ft-lb).
5.Install the Allen head race locknut set screw through the valve housing and tighten to 1.7-2.8 Nm (15-25 in-lb).
6.Place the piston on the bench with the ball guide holes facing up. Insert the worm into the piston so the first groove is in line with the hole nearest the center of the piston.
7.Place the ball guides in the piston. Turning the input shaft counterclockwise place the same balls as removed in Step 9 of Steering Gear Disassembly in the ball guide. During assembly 27 to 29 balls are required. If all the balls have not been inserted upon reaching the left stop rotate the input shaft in one direction then the other while inserting the remaining balls.


{tag}1250444254@

Steering Gear Assembly

8.Secure the guides in the ball nut with the clamp. Tighten screws to 4.8-7.9 Nm (42-70 in-lb).
9.Apply petroleum jelly or equivalent to the Teflon seal on the piston.
10.Place a new control valve O-ring on the valve housing.
11.Slide the piston and valve into the gear housing being careful not to damage the piston ring.
12.Align the oil passage in the valve housing with the passage in the gear housing. Place a new O-ring onto the oil passage hole of the gear housing. Install identification tag onto the housing. Install but do not tighten, the attaching bolts. Identification tag is to be installed under upper right valve housing bolt.
13.Rotate the piston so the teeth are in the same plane as the sector teeth. Tighten the valve housing attaching bolts to 40-60 Nm (30-45 ft-lb).
14.Position the sector shaft cover O-ring in the steering gear housing. Turn the input shaft to center the piston.
15.Apply petroleum jelly or equivalent to the sector shaft journal and position the sector shaft and cover assembly in the gear housing. Install the sector shaft cover attaching bolts. Tighten the bolts to 75-94 Nm (55-70 ft-lb).
16.Attach an inch-pound torque wrench to the input shaft. Adjust meshload to specification. Take the following precautions when servicing the steering gear:
1.Use a clean workbench and tools.
2.Thoroughly clean the exterior of the gear with solvent and drain off excess hydraulic fluid if necessary.
3.Handle all parts carefully to avoid nicks burrs scratches and dirt.
4.Do not use solvent on seals.

Steering Gear

Disassembly

1.Hold the steering gear upside down over a drain pan and cycle the input shaft several times to drain the fluid from the gear.


{tag}1250020219@


2.Secure the gear in a soft-jawed vise.
3.Turn the input shaft to either stop then turn it back two turns to center the gear.

NOTE: The indexing flat on the input shaft should be facing downward.

4.Remove the sector shaft cover attaching bolts.
5.Tap the lower end of the sector shaft with a soft hammer to loosen it and lift the cover and shaft from the housing as an assembly. Discard the O-ring.

NOTE: The following step is required only when it is necessary to remove sector shaft from the sector assembly.

6.Remove the nut from the sector shaft adjusting screw. Turn the sector shaft cover counterclockwise and remove it from the sector shaft adjuster screw.
7.Remove the valve housing attaching bolts and identification tag. Lift the valve housing off the steering gear housing. Remove the valve housing piston assembly and control valve gasket. Discard the gasket.

NOTE: If valve housing or the valve sleeve seals are to be replaced, proceed to Step 11. If sector shaft seals are to be replaced go to steering gear housing section. Balls need to be removed if valve sleeve rings are to be replaced.

8.With the piston held so the ball guide faces up remove the ball guide clamp screws and ball guide clamp.






9.With a finger over the opening in the ball guide turn the piston so the ball guide faces down over a clean container. Let the guide tubes drop into the container.
10.Rotate the input shaft from stop to stop until all balls fall from the piston into the container. The valve assembly can then be removed from the piston. Inspect the piston bore to make sure all balls have been removed.
11.Install the valve body assembly in the Bench Mounted Holding Fixture T57L-500-B and loosen the Allen head race locknut screw from the valve housing.
12.Remove the worm bearing race locknut using Adjuster and Locknut Wrench T66P-3553-B and Valve Housing to Piston Spacer T66P-3553-C.






13.Carefully slide the input shaft worm and valve assembly out of the valve housing.

Assembly

1.Mount the valve housing in the Bench Mounted Holding Fixture T57L-500-B with the flanged end up.
2.Apply a light coat of Premium Power Steering Fluid E6AZ-19582-AA (ESW-M2C33-F) or equivalent to the Teflon rings on the valve sleeve.
3.Carefully install the worm shaft and valve in the housing.
4.Install the worm bearing race locknut in the housing and tighten to 75-122 Nm (55-90 ft-lb).
5.Install the Allen head race locknut set screw through the valve housing and tighten to 1.7-2.8 Nm (15-25 in-lb).
6.Place the piston on the bench with the ball guide holes facing up. Insert the worm into the piston so the first groove is in line with the hole nearest the center of the piston.
7.Place the ball guides in the piston. Turning the input shaft counterclockwise place the same balls as removed in Step 9 of Steering Gear Disassembly in the ball guide. During assembly 27 to 29 balls are required. If all the balls have not been inserted upon reaching the left stop rotate the input shaft in one direction then the other while inserting the remaining balls.


{tag}1250444254@

Steering Gear Assembly

8.Secure the guides in the ball nut with the clamp. Tighten screws to 4.8-7.9 Nm (42-70 in-lb).
9.Apply petroleum jelly or equivalent to the Teflon seal on the piston.
10.Place a new control valve O-ring on the valve housing.
11.Slide the piston and valve into the gear housing being careful not to damage the piston ring.
12.Align the oil passage in the valve housing with the passage in the gear housing. Place a new O-ring onto the oil passage hole of the gear housing. Install identification tag onto the housing. Install but do not tighten, the attaching bolts. Identification tag is to be installed under upper right valve housing bolt.
13.Rotate the piston so the teeth are in the same plane as the sector teeth. Tighten the valve housing attaching bolts to 40-60 Nm (30-45 ft-lb).
14.Position the sector shaft cover O-ring in the steering gear housing. Turn the input shaft to center the piston.
15.Apply petroleum jelly or equivalent to the sector shaft journal and position the sector shaft and cover assembly in the gear housing. Install the sector shaft cover attaching bolts. Tighten the bolts to 75-94 Nm (55-70 ft-lb).
16.Attach an inch-pound torque wrench to the input shaft. Adjust meshload to specification. Take the following precautions when servicing the steering gear:
1.Use a clean workbench and tools.
2.Thoroughly clean the exterior of the gear with solvent and drain off excess hydraulic fluid if necessary.
3.Handle all parts carefully to avoid nicks burrs scratches and dirt.
4.Do not use solvent on seals.

Steering Gear

Disassembly

1.Hold the steering gear upside down over a drain pan and cycle the input shaft several times to drain the fluid from the gear.






2.Secure the gear in a soft-jawed vise.
3.Turn the input shaft to either stop then turn it back two turns to center the gear.

NOTE: The indexing flat on the input shaft should be facing downward.

4.Remove the sector shaft cover attaching bolts.
5.Tap the lower end of the sector shaft with a soft hammer to loosen it and lift the cover and shaft from the housing as an assembly. Discard the O-ring.

NOTE: The following step is required only when it is necessary to remove sector shaft from the sector assembly.

6.Remove the nut from the sector shaft adjusting screw. Turn the sector shaft cover counterclockwise and remove it from the sector shaft adjuster screw.
7.Remove the valve housing attaching bolts and identification tag. Lift the valve housing off the steering gear housing. Remove the valve housing piston assembly and control valve gasket. Discard the gasket.

NOTE: If valve housing or the valve sleeve seals are to be replaced, proceed to Step 11. If sector shaft seals are to be replaced go to steering gear housing section. Balls need to be removed if valve sleeve rings are to be replaced.

8.With the piston held so the ball guide faces up remove the ball guide clamp screws and ball guide clamp.






9.With a finger over the opening in the ball guide turn the piston so the ball guide faces down over a clean container. Let the guide tubes drop into the container.
10.Rotate the input shaft from stop to stop until all balls fall from the piston into the container. The valve assembly can then be removed from the piston. Inspect the piston bore to make sure all balls have been removed.
11.Install the valve body assembly in the Bench Mounted Holding Fixture T57L-500-B and loosen the Allen head race locknut screw from the valve housing.
12.Remove the worm bearing race locknut using Adjuster and Locknut Wrench T66P-3553-B and Valve Housing to Piston Spacer T66P-3553-C.






13.Carefully slide the input shaft worm and valve assembly out of the valve housing.

Assembly

1.Mount the valve housing in the Bench Mounted Holding Fixture T57L-500-B with the flanged end up.
2.Apply a light coat of Premium Power Steering Fluid E6AZ-19582-AA (ESW-M2C33-F) or equivalent to the Teflon rings on the valve sleeve.
3.Carefully install the worm shaft and valve in the housing.
4.Install the worm bearing race locknut in the housing and tighten to 75-122 Nm (55-90 ft-lb).
5.Install the Allen head race locknut set screw through the valve housing and tighten to 1.7-2.8 Nm (15-25 in-lb).
6.Place the piston on the bench with the ball guide holes facing up. Insert the worm into the piston so the first groove is in line with the hole nearest the center of the piston.
7.Place the ball guides in the piston. Turning the input shaft counterclockwise place the same balls as removed in Step 9 of Steering Gear Disassembly in the ball guide. During assembly 27 to 29 balls are required. If all the balls have not been inserted upon reaching the left stop rotate the input shaft in one direction then the other while inserting the remaining balls.


{tag}1250444254@

Steering Gear Assembly

8.Secure the guides in the ball nut with the clamp. Tighten screws to 4.8-7.9 Nm (42-70 in-lb).
9.Apply petroleum jelly or equivalent to the Teflon seal on the piston.
10.Place a new control valve O-ring on the valve housing.
11.Slide the piston and valve into the gear housing being careful not to damage the piston ring.
12.Align the oil passage in the valve housing with the passage in the gear housing. Place a new O-ring onto the oil passage hole of the gear housing. Install identification tag onto the housing. Install but do not tighten, the attaching bolts. Identification tag is to be installed under upper right valve housing bolt.
13.Rotate the piston so the teeth are in the same plane as the sector teeth. Tighten the valve housing attaching bolts to 40-60 Nm (30-45 ft-lb).
14.Position the sector shaft cover O-ring in the steering gear housing. Turn the input shaft to center the piston.
15.Apply petroleum jelly or equivalent to the sector shaft journal and position the sector shaft and cover assembly in the gear housing. Install the sector shaft cover attaching bolts. Tighten the bolts to 75-94 Nm (55-70 ft-lb).
16.Attach an inch-pound torque wrench to the input shaft. Adjust meshload to specification. Take the following precautions when servicing the steering gear:
1.Use a clean workbench and tools.
2.Thoroughly clean the exterior of the gear with solvent and drain off excess hydraulic fluid if necessary.
3.Handle all parts carefully to avoid nicks burrs scratches and dirt.
4.Do not use solvent on seals.

Steering Gear

Disassembly

1.Hold the steering gear upside down over a drain pan and cycle the input shaft several times to drain the fluid from the gear.


{tag}1250020219@


2.Secure the gear in a soft-jawed vise.
3.Turn the input shaft to either stop then turn it back two turns to center the gear.

NOTE: The indexing flat on the input shaft should be facing downward.

4.Remove the sector shaft cover attaching bolts.
5.Tap the lower end of the sector shaft with a soft hammer to loosen it and lift the cover and shaft from the housing as an assembly. Discard the O-ring.

NOTE: The following step is required only when it is necessary to remove sector shaft from the sector assembly.

6.Remove the nut from the sector shaft adjusting screw. Turn the sector shaft cover counterclockwise and remove it from the sector shaft adjuster screw.
7.Remove the valve housing attaching bolts and identification tag. Lift the valve housing off the steering gear housing. Remove the valve housing piston assembly and control valve gasket. Discard the gasket.

NOTE: If valve housing or the valve sleeve seals are to be replaced, proceed to Step 11. If sector shaft seals are to be replaced go to steering gear housing section. Balls need to be removed if valve sleeve rings are to be replaced.

8.With the piston held so the ball guide faces up remove the ball guide clamp screws and ball guide clamp.


{tag}1250145985@


9.With a finger over the opening in the ball guide turn the piston so the ball guide faces down over a clean container. Let the guide tubes drop into the container.
10.Rotate the input shaft from stop to stop until all balls fall from the piston into the container. The valve assembly can then be removed from the piston. Inspect the piston bore to make sure all balls have been removed.
11.Install the valve body assembly in the Bench Mounted Holding Fixture T57L-500-B and loosen the Allen head race locknut screw from the valve housing.
12.Remove the worm bearing race locknut using Adjuster and Locknut Wrench T66P-3553-B and Valve Housing to Piston Spacer T66P-3553-C.


{tag}1250267634@


13.Carefully slide the input shaft worm and valve assembly out of the valve housing.

Assembly

1.Mount the valve housing in the Bench Mounted Holding Fixture T57L-500-B with the flanged end up.
2.Apply a light coat of Premium Power Steering Fluid E6AZ-19582-AA (ESW-M2C33-F) or equivalent to the Teflon rings on the valve sleeve.
3.Carefully install the worm shaft and valve in the housing.
4.Install the worm bearing race locknut in the housing and tighten to 75-122 Nm (55-90 ft-lb).
5.Install the Allen head race locknut set screw through the valve housing and tighten to 1.7-2.8 Nm (15-25 in-lb).
6.Place the piston on the bench with the ball guide holes facing up. Insert the worm into the piston so the first groove is in line with the hole nearest the center of the piston.
7.Place the ball guides in the piston. Turning the input shaft counterclockwise place the same balls as removed in Step 9 of Steering Gear Disassembly in the ball guide. During assembly 27 to 29 balls are required. If all the balls have not been inserted upon reaching the left stop rotate the input shaft in one direction then the other while inserting the remaining balls.





Steering Gear Assembly

8.Secure the guides in the ball nut with the clamp. Tighten screws to 4.8-7.9 Nm (42-70 in-lb).
9.Apply petroleum jelly or equivalent to the Teflon seal on the piston.
10.Place a new control valve O-ring on the valve housing.
11.Slide the piston and valve into the gear housing being careful not to damage the piston ring.
12.Align the oil passage in the valve housing with the passage in the gear housing. Place a new O-ring onto the oil passage hole of the gear housing. Install identification tag onto the housing. Install but do not tighten, the attaching bolts. Identification tag is to be installed under upper right valve housing bolt.
13.Rotate the piston so the teeth are in the same plane as the sector teeth. Tighten the valve housing attaching bolts to 40-60 Nm (30-45 ft-lb).
14.Position the sector shaft cover O-ring in the steering gear housing. Turn the input shaft to center the piston.
15.Apply petroleum jelly or equivalent to the sector shaft journal and position the sector shaft and cover assembly in the gear housing. Install the sector shaft cover attaching bolts. Tighten the bolts to 75-94 Nm (55-70 ft-lb).
16.Attach an inch-pound torque wrench to the input shaft. Adjust meshload to specification. Take the following precautions when servicing the steering gear:
1.Use a clean workbench and tools.
2.Thoroughly clean the exterior of the gear with solvent and drain off excess hydraulic fluid if necessary.
3.Handle all parts carefully to avoid nicks burrs scratches and dirt.
4.Do not use solvent on seals.

Steering Gear

Disassembly

1.Hold the steering gear upside down over a drain pan and cycle the input shaft several times to drain the fluid from the gear.






2.Secure the gear in a soft-jawed vise.
3.Turn the input shaft to either stop then turn it back two turns to center the gear.

NOTE: The indexing flat on the input shaft should be facing downward.

4.Remove the sector shaft cover attaching bolts.
5.Tap the lower end of the sector shaft with a soft hammer to loosen it and lift the cover and shaft from the housing as an assembly. Discard the O-ring.

NOTE: The following step is required only when it is necessary to remove sector shaft from the sector assembly.

6.Remove the nut from the sector shaft adjusting screw. Turn the sector shaft cover counterclockwise and remove it from the sector shaft adjuster screw.
7.Remove the valve housing attaching bolts and identification tag. Lift the valve housing off the steering gear housing. Remove the valve housing piston assembly and control valve gasket. Discard the gasket.

NOTE: If valve housing or the valve sleeve seals are to be replaced, proceed to Step 11. If sector shaft seals are to be replaced go to steering gear housing section. Balls need to be removed if valve sleeve rings are to be replaced.

8.With the piston held so the ball guide faces up remove the ball guide clamp screws and ball guide clamp.


{tag}1250145985@


9.With a finger over the opening in the ball guide turn the piston so the ball guide faces down over a clean container. Let the guide tubes drop into the container.
10.Rotate the input shaft from stop to stop until all balls fall from the piston into the container. The valve assembly can then be removed from the piston. Inspect the piston bore to make sure all balls have been removed.
11.Install the valve body assembly in the Bench Mounted Holding Fixture T57L-500-B and loosen the Allen head race locknut screw from the valve housing.
12.Remove the worm bearing race locknut using Adjuster and Locknut Wrench T66P-3553-B and Valve Housing to Piston Spacer T66P-3553-C.


{tag}1250267634@


13.Carefully slide the input shaft worm and valve assembly out of the valve housing.

Assembly

1.Mount the valve housing in the Bench Mounted Holding Fixture T57L-500-B with the flanged end up.
2.Apply a light coat of Premium Power Steering Fluid E6AZ-19582-AA (ESW-M2C33-F) or equivalent to the Teflon rings on the valve sleeve.
3.Carefully install the worm shaft and valve in the housing.
4.Install the worm bearing race locknut in the housing and tighten to 75-122 Nm (55-90 ft-lb).
5.Install the Allen head race locknut set screw through the valve housing and tighten to 1.7-2.8 Nm (15-25 in-lb).
6.Place the piston on the bench with the ball guide holes facing up. Insert the worm into the piston so the first groove is in line with the hole nearest the center of the piston.
7.Place the ball guides in the piston. Turning the input shaft counterclockwise place the same balls as removed in Step 9 of Steering Gear Disassembly in the ball guide. During assembly 27 to 29 balls are required. If all the balls have not been inserted upon reaching the left stop rotate the input shaft in one direction then the other while inserting the remaining balls.





Steering Gear Assembly

8.Secure the guides in the ball nut with the clamp. Tighten screws to 4.8-7.9 Nm (42-70 in-lb).
9.Apply petroleum jelly or equivalent to the Teflon seal on the piston.
10.Place a new control valve O-ring on the valve housing.
11.Slide the piston and valve into the gear housing being careful not to damage the piston ring.
12.Align the oil passage in the valve housing with the passage in the gear housing. Place a new O-ring onto the oil passage hole of the gear housing. Install identification tag onto the housing. Install but do not tighten, the attaching bolts. Identification tag is to be installed under upper right valve housing bolt.
13.Rotate the piston so the teeth are in the same plane as the sector teeth. Tighten the valve housing attaching bolts to 40-60 Nm (30-45 ft-lb).
14.Position the sector shaft cover O-ring in the steering gear housing. Turn the input shaft to center the piston.
15.Apply petroleum jelly or equivalent to the sector shaft journal and position the sector shaft and cover assembly in the gear housing. Install the sector shaft cover attaching bolts. Tighten the bolts to 75-94 Nm (55-70 ft-lb).
16.Attach an inch-pound torque wrench to the input shaft. Adjust meshload to specification. Take the following precautions when servicing the steering gear:
1.Use a clean workbench and tools.
2.Thoroughly clean the exterior of the gear with solvent and drain off excess hydraulic fluid if necessary.
3.Handle all parts carefully to avoid nicks burrs scratches and dirt.
4.Do not use solvent on seals.

Steering Gear

Disassembly

1.Hold the steering gear upside down over a drain pan and cycle the input shaft several times to drain the fluid from the gear.


{tag}1250020219@


2.Secure the gear in a soft-jawed vise.
3.Turn the input shaft to either stop then turn it back two turns to center the gear.

NOTE: The indexing flat on the input shaft should be facing downward.

4.Remove the sector shaft cover attaching bolts.
5.Tap the lower end of the sector shaft with a soft hammer to loosen it and lift the cover and shaft from the housing as an assembly. Discard the O-ring.

NOTE: The following step is required only when it is necessary to remove sector shaft from the sector assembly.

6.Remove the nut from the sector shaft adjusting screw. Turn the sector shaft cover counterclockwise and remove it from the sector shaft adjuster screw.
7.Remove the valve housing attaching bolts and identification tag. Lift the valve housing off the steering gear housing. Remove the valve housing piston assembly and control valve gasket. Discard the gasket.

NOTE: If valve housing or the valve sleeve seals are to be replaced, proceed to Step 11. If sector shaft seals are to be replaced go to steering gear housing section. Balls need to be removed if valve sleeve rings are to be replaced.

8.With the piston held so the ball guide faces up remove the ball guide clamp screws and ball guide clamp.






9.With a finger over the opening in the ball guide turn the piston so the ball guide faces down over a clean container. Let the guide tubes drop into the container.
10.Rotate the input shaft from stop to stop until all balls fall from the piston into the container. The valve assembly can then be removed from the piston. Inspect the piston bore to make sure all balls have been removed.
11.Install the valve body assembly in the Bench Mounted Holding Fixture T57L-500-B and loosen the Allen head race locknut screw from the valve housing.
12.Remove the worm bearing race locknut using Adjuster and Locknut Wrench T66P-3553-B and Valve Housing to Piston Spacer T66P-3553-C.


{tag}1250267634@


13.Carefully slide the input shaft worm and valve assembly out of the valve housing.

Assembly

1.Mount the valve housing in the Bench Mounted Holding Fixture T57L-500-B with the flanged end up.
2.Apply a light coat of Premium Power Steering Fluid E6AZ-19582-AA (ESW-M2C33-F) or equivalent to the Teflon rings on the valve sleeve.
3.Carefully install the worm shaft and valve in the housing.
4.Install the worm bearing race locknut in the housing and tighten to 75-122 Nm (55-90 ft-lb).
5.Install the Allen head race locknut set screw through the valve housing and tighten to 1.7-2.8 Nm (15-25 in-lb).
6.Place the piston on the bench with the ball guide holes facing up. Insert the worm into the piston so the first groove is in line with the hole nearest the center of the piston.
7.Place the ball guides in the piston. Turning the input shaft counterclockwise place the same balls as removed in Step 9 of Steering Gear Disassembly in the ball guide. During assembly 27 to 29 balls are required. If all the balls have not been inserted upon reaching the left stop rotate the input shaft in one direction then the other while inserting the remaining balls.





Steering Gear Assembly

8.Secure the guides in the ball nut with the clamp. Tighten screws to 4.8-7.9 Nm (42-70 in-lb).
9.Apply petroleum jelly or equivalent to the Teflon seal on the piston.
10.Place a new control valve O-ring on the valve housing.
11.Slide the piston and valve into the gear housing being careful not to damage the piston ring.
12.Align the oil passage in the valve housing with the passage in the gear housing. Place a new O-ring onto the oil passage hole of the gear housing. Install identification tag onto the housing. Install but do not tighten, the attaching bolts. Identification tag is to be installed under upper right valve housing bolt.
13.Rotate the piston so the teeth are in the same plane as the sector teeth. Tighten the valve housing attaching bolts to 40-60 Nm (30-45 ft-lb).
14.Position the sector shaft cover O-ring in the steering gear housing. Turn the input shaft to center the piston.
15.Apply petroleum jelly or equivalent to the sector shaft journal and position the sector shaft and cover assembly in the gear housing. Install the sector shaft cover attaching bolts. Tighten the bolts to 75-94 Nm (55-70 ft-lb).
16.Attach an inch-pound torque wrench to the input shaft. Adjust meshload to specification. Take the following precautions when servicing the steering gear:
1.Use a clean workbench and tools.
2.Thoroughly clean the exterior of the gear with solvent and drain off excess hydraulic fluid if necessary.
3.Handle all parts carefully to avoid nicks burrs scratches and dirt.
4.Do not use solvent on seals.

Steering Gear

Disassembly

1.Hold the steering gear upside down over a drain pan and cycle the input shaft several times to drain the fluid from the gear.






2.Secure the gear in a soft-jawed vise.
3.Turn the input shaft to either stop then turn it back two turns to center the gear.

NOTE: The indexing flat on the input shaft should be facing downward.

4.Remove the sector shaft cover attaching bolts.
5.Tap the lower end of the sector shaft with a soft hammer to loosen it and lift the cover and shaft from the housing as an assembly. Discard the O-ring.

NOTE: The following step is required only when it is necessary to remove sector shaft from the sector assembly.

6.Remove the nut from the sector shaft adjusting screw. Turn the sector shaft cover counterclockwise and remove it from the sector shaft adjuster screw.
7.Remove the valve housing attaching bolts and identification tag. Lift the valve housing off the steering gear housing. Remove the valve housing piston assembly and control valve gasket. Discard the gasket.

NOTE: If valve housing or the valve sleeve seals are to be replaced, proceed to Step 11. If sector shaft seals are to be replaced go to steering gear housing section. Balls need to be removed if valve sleeve rings are to be replaced.

8.With the piston held so the ball guide faces up remove the ball guide clamp screws and ball guide clamp.






9.With a finger over the opening in the ball guide turn the piston so the ball guide faces down over a clean container. Let the guide tubes drop into the container.
10.Rotate the input shaft from stop to stop until all balls fall from the piston into the container. The valve assembly can then be removed from the piston. Inspect the piston bore to make sure all balls have been removed.
11.Install the valve body assembly in the Bench Mounted Holding Fixture T57L-500-B and loosen the Allen head race locknut screw from the valve housing.
12.Remove the worm bearing race locknut using Adjuster and Locknut Wrench T66P-3553-B and Valve Housing to Piston Spacer T66P-3553-C.


{tag}1250267634@


13.Carefully slide the input shaft worm and valve assembly out of the valve housing.

Assembly

1.Mount the valve housing in the Bench Mounted Holding Fixture T57L-500-B with the flanged end up.
2.Apply a light coat of Premium Power Steering Fluid E6AZ-19582-AA (ESW-M2C33-F) or equivalent to the Teflon rings on the valve sleeve.
3.Carefully install the worm shaft and valve in the housing.
4.Install the worm bearing race locknut in the housing and tighten to 75-122 Nm (55-90 ft-lb).
5.Install the Allen head race locknut set screw through the valve housing and tighten to 1.7-2.8 Nm (15-25 in-lb).
6.Place the piston on the bench with the ball guide holes facing up. Insert the worm into the piston so the first groove is in line with the hole nearest the center of the piston.
7.Place the ball guides in the piston. Turning the input shaft counterclockwise place the same balls as removed in Step 9 of Steering Gear Disassembly in the ball guide. During assembly 27 to 29 balls are required. If all the balls have not been inserted upon reaching the left stop rotate the input shaft in one direction then the other while inserting the remaining balls.





Steering Gear Assembly

8.Secure the guides in the ball nut with the clamp. Tighten screws to 4.8-7.9 Nm (42-70 in-lb).
9.Apply petroleum jelly or equivalent to the Teflon seal on the piston.
10.Place a new control valve O-ring on the valve housing.
11.Slide the piston and valve into the gear housing being careful not to damage the piston ring.
12.Align the oil passage in the valve housing with the passage in the gear housing. Place a new O-ring onto the oil passage hole of the gear housing. Install identification tag onto the housing. Install but do not tighten, the attaching bolts. Identification tag is to be installed under upper right valve housing bolt.
13.Rotate the piston so the teeth are in the same plane as the sector teeth. Tighten the valve housing attaching bolts to 40-60 Nm (30-45 ft-lb).
14.Position the sector shaft cover O-ring in the steering gear housing. Turn the input shaft to center the piston.
15.Apply petroleum jelly or equivalent to the sector shaft journal and position the sector shaft and cover assembly in the gear housing. Install the sector shaft cover attaching bolts. Tighten the bolts to 75-94 Nm (55-70 ft-lb).
16.Attach an inch-pound torque wrench to the input shaft. Adjust meshload to specification. Take the following precautions when servicing the steering gear:
1.Use a clean workbench and tools.
2.Thoroughly clean the exterior of the gear with solvent and drain off excess hydraulic fluid if necessary.
3.Handle all parts carefully to avoid nicks burrs scratches and dirt.
4.Do not use solvent on seals.

Steering Gear

Disassembly

1.Hold the steering gear upside down over a drain pan and cycle the input shaft several times to drain the fluid from the gear.


{tag}1250020219@


2.Secure the gear in a soft-jawed vise.
3.Turn the input shaft to either stop then turn it back two turns to center the gear.

NOTE: The indexing flat on the input shaft should be facing downward.

4.Remove the sector shaft cover attaching bolts.
5.Tap the lower end of the sector shaft with a soft hammer to loosen it and lift the cover and shaft from the housing as an assembly. Discard the O-ring.

NOTE: The following step is required only when it is necessary to remove sector shaft from the sector assembly.

6.Remove the nut from the sector shaft adjusting screw. Turn the sector shaft cover counterclockwise and remove it from the sector shaft adjuster screw.
7.Remove the valve housing attaching bolts and identification tag. Lift the valve housing off the steering gear housing. Remove the valve housing piston assembly and control valve gasket. Discard the gasket.

NOTE: If valve housing or the valve sleeve seals are to be replaced, proceed to Step 11. If sector shaft seals are to be replaced go to steering gear housing section. Balls need to be removed if valve sleeve rings are to be replaced.

8.With the piston held so the ball guide faces up remove the ball guide clamp screws and ball guide clamp.


{tag}1250145985@


9.With a finger over the opening in the ball guide turn the piston so the ball guide faces down over a clean container. Let the guide tubes drop into the container.
10.Rotate the input shaft from stop to stop until all balls fall from the piston into the container. The valve assembly can then be removed from the piston. Inspect the piston bore to make sure all balls have been removed.
11.Install the valve body assembly in the Bench Mounted Holding Fixture T57L-500-B and loosen the Allen head race locknut screw from the valve housing.
12.Remove the worm bearing race locknut using Adjuster and Locknut Wrench T66P-3553-B and Valve Housing to Piston Spacer T66P-3553-C.






13.Carefully slide the input shaft worm and valve assembly out of the valve housing.

Assembly

1.Mount the valve housing in the Bench Mounted Holding Fixture T57L-500-B with the flanged end up.
2.Apply a light coat of Premium Power Steering Fluid E6AZ-19582-AA (ESW-M2C33-F) or equivalent to the Teflon rings on the valve sleeve.
3.Carefully install the worm shaft and valve in the housing.
4.Install the worm bearing race locknut in the housing and tighten to 75-122 Nm (55-90 ft-lb).
5.Install the Allen head race locknut set screw through the valve housing and tighten to 1.7-2.8 Nm (15-25 in-lb).
6.Place the piston on the bench with the ball guide holes facing up. Insert the worm into the piston so the first groove is in line with the hole nearest the center of the piston.
7.Place the ball guides in the piston. Turning the input shaft counterclockwise place the same balls as removed in Step 9 of Steering Gear Disassembly in the ball guide. During assembly 27 to 29 balls are required. If all the balls have not been inserted upon reaching the left stop rotate the input shaft in one direction then the other while inserting the remaining balls.





Steering Gear Assembly

8.Secure the guides in the ball nut with the clamp. Tighten screws to 4.8-7.9 Nm (42-70 in-lb).
9.Apply petroleum jelly or equivalent to the Teflon seal on the piston.
10.Place a new control valve O-ring on the valve housing.
11.Slide the piston and valve into the gear housing being careful not to damage the piston ring.
12.Align the oil passage in the valve housing with the passage in the gear housing. Place a new O-ring onto the oil passage hole of the gear housing. Install identification tag onto the housing. Install but do not tighten, the attaching bolts. Identification tag is to be installed under upper right valve housing bolt.
13.Rotate the piston so the teeth are in the same plane as the sector teeth. Tighten the valve housing attaching bolts to 40-60 Nm (30-45 ft-lb).
14.Position the sector shaft cover O-ring in the steering gear housing. Turn the input shaft to center the piston.
15.Apply petroleum jelly or equivalent to the sector shaft journal and position the sector shaft and cover assembly in the gear housing. Install the sector shaft cover attaching bolts. Tighten the bolts to 75-94 Nm (55-70 ft-lb).
16.Attach an inch-pound torque wrench to the input shaft. Adjust meshload to specification. Take the following precautions when servicing the steering gear:
1.Use a clean workbench and tools.
2.Thoroughly clean the exterior of the gear with solvent and drain off excess hydraulic fluid if necessary.
3.Handle all parts carefully to avoid nicks burrs scratches and dirt.
4.Do not use solvent on seals.

Steering Gear

Disassembly

1.Hold the steering gear upside down over a drain pan and cycle the input shaft several times to drain the fluid from the gear.






2.Secure the gear in a soft-jawed vise.
3.Turn the input shaft to either stop then turn it back two turns to center the gear.

NOTE: The indexing flat on the input shaft should be facing downward.

4.Remove the sector shaft cover attaching bolts.
5.Tap the lower end of the sector shaft with a soft hammer to loosen it and lift the cover and shaft from the housing as an assembly. Discard the O-ring.

NOTE: The following step is required only when it is necessary to remove sector shaft from the sector assembly.

6.Remove the nut from the sector shaft adjusting screw. Turn the sector shaft cover counterclockwise and remove it from the sector shaft adjuster screw.
7.Remove the valve housing attaching bolts and identification tag. Lift the valve housing off the steering gear housing. Remove the valve housing piston assembly and control valve gasket. Discard the gasket.

NOTE: If valve housing or the valve sleeve seals are to be replaced, proceed to Step 11. If sector shaft seals are to be replaced go to steering gear housing section. Balls need to be removed if valve sleeve rings are to be replaced.

8.With the piston held so the ball guide faces up remove the ball guide clamp screws and ball guide clamp.


{tag}1250145985@


9.With a finger over the opening in the ball guide turn the piston so the ball guide faces down over a clean container. Let the guide tubes drop into the container.
10.Rotate the input shaft from stop to stop until all balls fall from the piston into the container. The valve assembly can then be removed from the piston. Inspect the piston bore to make sure all balls have been removed.
11.Install the valve body assembly in the Bench Mounted Holding Fixture T57L-500-B and loosen the Allen head race locknut screw from the valve housing.
12.Remove the worm bearing race locknut using Adjuster and Locknut Wrench T66P-3553-B and Valve Housing to Piston Spacer T66P-3553-C.






13.Carefully slide the input shaft worm and valve assembly out of the valve housing.

Assembly

1.Mount the valve housing in the Bench Mounted Holding Fixture T57L-500-B with the flanged end up.
2.Apply a light coat of Premium Power Steering Fluid E6AZ-19582-AA (ESW-M2C33-F) or equivalent to the Teflon rings on the valve sleeve.
3.Carefully install the worm shaft and valve in the housing.
4.Install the worm bearing race locknut in the housing and tighten to 75-122 Nm (55-90 ft-lb).
5.Install the Allen head race locknut set screw through the valve housing and tighten to 1.7-2.8 Nm (15-25 in-lb).
6.Place the piston on the bench with the ball guide holes facing up. Insert the worm into the piston so the first groove is in line with the hole nearest the center of the piston.
7.Place the ball guides in the piston. Turning the input shaft counterclockwise place the same balls as removed in Step 9 of Steering Gear Disassembly in the ball guide. During assembly 27 to 29 balls are required. If all the balls have not been inserted upon reaching the left stop rotate the input shaft in one direction then the other while inserting the remaining balls.





Steering Gear Assembly

8.Secure the guides in the ball nut with the clamp. Tighten screws to 4.8-7.9 Nm (42-70 in-lb).
9.Apply petroleum jelly or equivalent to the Teflon seal on the piston.
10.Place a new control valve O-ring on the valve housing.
11.Slide the piston and valve into the gear housing being careful not to damage the piston ring.
12.Align the oil passage in the valve housing with the passage in the gear housing. Place a new O-ring onto the oil passage hole of the gear housing. Install identification tag onto the housing. Install but do not tighten, the attaching bolts. Identification tag is to be installed under upper right valve housing bolt.
13.Rotate the piston so the teeth are in the same plane as the sector teeth. Tighten the valve housing attaching bolts to 40-60 Nm (30-45 ft-lb).
14.Position the sector shaft cover O-ring in the steering gear housing. Turn the input shaft to center the piston.
15.Apply petroleum jelly or equivalent to the sector shaft journal and position the sector shaft and cover assembly in the gear housing. Install the sector shaft cover attaching bolts. Tighten the bolts to 75-94 Nm (55-70 ft-lb).
16.Attach an inch-pound torque wrench to the input shaft. Adjust meshload to specification. Take the following precautions when servicing the steering gear:
1.Use a clean workbench and tools.
2.Thoroughly clean the exterior of the gear with solvent and drain off excess hydraulic fluid if necessary.
3.Handle all parts carefully to avoid nicks burrs scratches and dirt.
4.Do not use solvent on seals.

Steering Gear

Disassembly

1.Hold the steering gear upside down over a drain pan and cycle the input shaft several times to drain the fluid from the gear.


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2.Secure the gear in a soft-jawed vise.
3.Turn the input shaft to either stop then turn it back two turns to center the gear.

NOTE: The indexing flat on the input shaft should be facing downward.

4.Remove the sector shaft cover attaching bolts.
5.Tap the lower end of the sector shaft with a soft hammer to loosen it and lift the cover and shaft from the housing as an assembly. Discard the O-ring.

NOTE: The following step is required only when it is necessary to remove sector shaft from the sector assembly.

6.Remove the nut from the sector shaft adjusting screw. Turn the sector shaft cover counterclockwise and remove it from the sector shaft adjuster screw.
7.Remove the valve housing attaching bolts and identification tag. Lift the valve housing off the steering gear housing. Remove the valve housing piston assembly and control valve gasket. Discard the gasket.

NOTE: If valve housing or the valve sleeve seals are to be replaced, proceed to Step 11. If sector shaft seals are to be replaced go to steering gear housing section. Balls need to be removed if valve sleeve rings are to be replaced.

8.With the piston held so the ball guide faces up remove the ball guide clamp screws and ball guide clamp.






9.With a finger over the opening in the ball guide turn the piston so the ball guide faces down over a clean container. Let the guide tubes drop into the container.
10.Rotate the input shaft from stop to stop until all balls fall from the piston into the container. The valve assembly can then be removed from the piston. Inspect the piston bore to make sure all balls have been removed.
11.Install the valve body assembly in the Bench Mounted Holding Fixture T57L-500-B and loosen the Allen head race locknut screw from the valve housing.
12.Remove the worm bearing race locknut using Adjuster and Locknut Wrench T66P-3553-B and Valve Housing to Piston Spacer T66P-3553-C.






13.Carefully slide the input shaft worm and valve assembly out of the valve housing.

Assembly

1.Mount the valve housing in the Bench Mounted Holding Fixture T57L-500-B with the flanged end up.
2.Apply a light coat of Premium Power Steering Fluid E6AZ-19582-AA (ESW-M2C33-F) or equivalent to the Teflon rings on the valve sleeve.
3.Carefully install the worm shaft and valve in the housing.
4.Install the worm bearing race locknut in the housing and tighten to 75-122 Nm (55-90 ft-lb).
5.Install the Allen head race locknut set screw through the valve housing and tighten to 1.7-2.8 Nm (15-25 in-lb).
6.Place the piston on the bench with the ball guide holes facing up. Insert the worm into the piston so the first groove is in line with the hole nearest the center of the piston.
7.Place the ball guides in the piston. Turning the input shaft counterclockwise place the same balls as removed in Step 9 of Steering Gear Disassembly in the ball guide. During assembly 27 to 29 balls are required. If all the balls have not been inserted upon reaching the left stop rotate the input shaft in one direction then the other while inserting the remaining balls.





Steering Gear Assembly

8.Secure the guides in the ball nut with the clamp. Tighten screws to 4.8-7.9 Nm (42-70 in-lb).
9.Apply petroleum jelly or equivalent to the Teflon seal on the piston.
10.Place a new control valve O-ring on the valve housing.
11.Slide the piston and valve into the gear housing being careful not to damage the piston ring.
12.Align the oil passage in the valve housing with the passage in the gear housing. Place a new O-ring onto the oil passage hole of the gear housing. Install identification tag onto the housing. Install but do not tighten, the attaching bolts. Identification tag is to be installed under upper right valve housing bolt.
13.Rotate the piston so the teeth are in the same plane as the sector teeth. Tighten the valve housing attaching bolts to 40-60 Nm (30-45 ft-lb).
14.Position the sector shaft cover O-ring in the steering gear housing. Turn the input shaft to center the piston.
15.Apply petroleum jelly or equivalent to the sector shaft journal and position the sector shaft and cover assembly in the gear housing. Install the sector shaft cover attaching bolts. Tighten the bolts to 75-94 Nm (55-70 ft-lb).
16.Attach an inch-pound torque wrench to the input shaft. Adjust meshload to specification. Take the following precautions when servicing the steering gear:
1.Use a clean workbench and tools.
2.Thoroughly clean the exterior of the gear with solvent and drain off excess hydraulic fluid if necessary.
3.Handle all parts carefully to avoid nicks burrs scratches and dirt.
4.Do not use solvent on seals.

Steering Gear

Disassembly

1.Hold the steering gear upside down over a drain pan and cycle the input shaft several times to drain the fluid from the gear.






2.Secure the gear in a soft-jawed vise.
3.Turn the input shaft to either stop then turn it back two turns to center the gear.

NOTE: The indexing flat on the input shaft should be facing downward.

4.Remove the sector shaft cover attaching bolts.
5.Tap the lower end of the sector shaft with a soft hammer to loosen it and lift the cover and shaft from the housing as an assembly. Discard the O-ring.

NOTE: The following step is required only when it is necessary to remove sector shaft from the sector assembly.

6.Remove the nut from the sector shaft adjusting screw. Turn the sector shaft cover counterclockwise and remove it from the sector shaft adjuster screw.
7.Remove the valve housing attaching bolts and identification tag. Lift the valve housing off the steering gear housing. Remove the valve housing piston assembly and control valve gasket. Discard the gasket.

NOTE: If valve housing or the valve sleeve seals are to be replaced, proceed to Step 11. If sector shaft seals are to be replaced go to steering gear housing section. Balls need to be removed if valve sleeve rings are to be replaced.

8.With the piston held so the ball guide faces up remove the ball guide clamp screws and ball guide clamp.






9.With a finger over the opening in the ball guide turn the piston so the ball guide faces down over a clean container. Let the guide tubes drop into the container.
10.Rotate the input shaft from stop to stop until all balls fall from the piston into the container. The valve assembly can then be removed from the piston. Inspect the piston bore to make sure all balls have been removed.
11.Install the valve body assembly in the Bench Mounted Holding Fixture T57L-500-B and loosen the Allen head race locknut screw from the valve housing.
12.Remove the worm bearing race locknut using Adjuster and Locknut Wrench T66P-3553-B and Valve Housing to Piston Spacer T66P-3553-C.






13.Carefully slide the input shaft worm and valve assembly out of the valve housing.

Assembly

1.Mount the valve housing in the Bench Mounted Holding Fixture T57L-500-B with the flanged end up.
2.Apply a light coat of Premium Power Steering Fluid E6AZ-19582-AA (ESW-M2C33-F) or equivalent to the Teflon rings on the valve sleeve.
3.Carefully install the worm shaft and valve in the housing.
4.Install the worm bearing race locknut in the housing and tighten to 75-122 Nm (55-90 ft-lb).
5.Install the Allen head race locknut set screw through the valve housing and tighten to 1.7-2.8 Nm (15-25 in-lb).
6.Place the piston on the bench with the ball guide holes facing up. Insert the worm into the piston so the first groove is in line with the hole nearest the center of the piston.
7.Place the ball guides in the piston. Turning the input shaft counterclockwise place the same balls as removed in Step 9 of Steering Gear Disassembly in the ball guide. During assembly 27 to 29 balls are required. If all the balls have not been inserted upon reaching the left stop rotate the input shaft in one direction then the other while inserting the remaining balls.





Steering Gear Assembly

8.Secure the guides in the ball nut with the clamp. Tighten screws to 4.8-7.9 Nm (42-70 in-lb).
9.Apply petroleum jelly or equivalent to the Teflon seal on the piston.
10.Place a new control valve O-ring on the valve housing.
11.Slide the piston and valve into the gear housing being careful not to damage the piston ring.
12.Align the oil passage in the valve housing with the passage in the gear housing. Place a new O-ring onto the oil passage hole of the gear housing. Install identification tag onto the housing. Install but do not tighten, the attaching bolts. Identification tag is to be installed under upper right valve housing bolt.
13.Rotate the piston so the teeth are in the same plane as the sector teeth. Tighten the valve housing attaching bolts to 40-60 Nm (30-45 ft-lb).
14.Position the sector shaft cover O-ring in the steering gear housing. Turn the input shaft to center the piston.
15.Apply petroleum jelly or equivalent to the sector shaft journal and position the sector shaft and cover assembly in the gear housing. Install the sector shaft cover attaching bolts. Tighten the bolts to 75-94 Nm (55-70 ft-lb).
16.Attach an inch-pound torque wrench to the input shaft. Adjust meshload to specification.


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