Skylark L4-138 2.3L DOHC VIN D MFI QUAD 4 (1989)
removal.
6.
Remove piston rod guide rack from housing and disassemble as follows:
a. Remove hex nut from rod and rack assembly.
b. Remove rack piston, containing O-ring seal, and piston ring, piston rod guide assembly, consisting of piston rod guide, O-ring seal, piston rod
seal and seal backup washer for rod and rack assembly.
c. Remove O-ring seal and piston rod seal from from piston rod guide.
7.
Remove retaining ring from housing.
8.
Remove pinion bearing assembly from housing.
9.
Remove pinion shaft seal and upper pinion bushing from housing.
10.
Coat all seals with power steering fluid.
11.
Install upper pinion bushing into valve bore in housing.
12.
Using seal installer, tool No. J 29822 or equivalent, seat pinion shaft seal into housing.
13.
Using suitable press, install pinion bearing assembly into housing.
14.
Install retaining ring in groove in housing, positioning properly.
15.
Assemble piston rod seal and O-ring seal to piston rod guide.
16.
Assemble O-ring seal and piston ring to rack piston.
17.
Slide seal backup washer, piston rod guide assembly and rack piston onto rod and rack assembly.
18.
Install hex nut on rod and rack assembly, on all models except LeMans torque to 30 ft. lbs., on LeMans models, torque to 22 ft. lbs.
19.
Slide piston rod guide assembly into housing.
20.
Apply one small drop of Loctite 242 or equivalent in three equally spaced locations around the threaded portion of housing. Be sure to use the
Loctite 242 sparingly to ensure ease of removal of cylinder tube assembly if future repairs are necessary.
21.
Slide cylinder tube assembly over rack piston ring to housing, then, using torque wrench or equivalent, torque to 82 ft. lbs. Be sure to align
fittings on cylinder tube with mark on housing before tightening to ensure cylinder line installation.
22.
Assemble insert and rack guide assembly to rod and rack assembly in housing.
23.
Center rack guide assembly in housing window opening.
24.
Using protector tool, No. J 33057 or equivalent, install pinion and valve assembly, together with new valve body rings, and spool shaft retaining
ring into housing. When pinion and valve assembly is fully seated in housing, notch in stub shaft and mark on housing line up and insert
and rack guide assembly is centered in window housing.
25.
While holding stub shaft, tighten locknut to 26 ft. lbs.
26.
Install dust cover on housing.
27.
Install stub shaft bearing annulus assembly onto stub shaft and slide into housing.
28.
Place seal protector, tool No. J 29810 or equivalent onto stub shaft, then slide stub shaft seal and stub shaft dust seal over protector and into
housing.
29.
Install retaining ring into groove in housing.
30.
Coat rack bearing, with O-ring seal attached, adjuster spring and the adjuster plug with lithium base grease and install in housing.
31.
With rack centered in window in housing, turn adjuster plug clockwise until it bottoms in housing, then back off 50-70°. Check pinion preload
torque, which should not exceed 16 inch lbs.
32.
Install locknut on adjuster plug and torque to 50 ft. lbs. while holding adjuster plug stationary.
