Aerostar 2WD V6-182 3.0L (1995)
12. Remove rack bushing seal by gripping seal in vise and squeezing seal to distort it, then pry out with screwdriver.
ASSEMBLE
1. Mark center tooth (11th tooth) on rack so that mark will be visible in valve bore.
2. Slide ring replacer tool No. T74P-3504-G, or equivalent, on rack until it seats on piston, then install rubber O-ring in rack piston groove.
3. Slide plastic O-ring over tool into piston groove over rubber O-ring.
4. Remove and retain plastic insert from rack seal.
5. Install rack seal protector tool No. T85L-3504-B, or equivalent, over rack teeth.
6. Lubricate rack and tool with suitable lubricant.
7. Install seal so that lip faces toward piston. Push seal all the way against piston. Remove rack seal protector.
Fig. 4 Installing Plastic Insert In Rack Seal
8. Install plastic insert into rack seal.
9. Pack rack teeth with suitable lubricant and apply light coat of lubricant to yoke contact area in back of rack teeth.
10. Apply suitable lubricant to piston seal and rack seal outside diameter.
11. Install Teflon(R) ring sizing tool No. T78P-3504-M, or equivalent, into end of gear housing.
12. Install rack, being careful not to scratch housing piston bore.
13. Carefully push piston through sizing tool, pushing on rack until it bottoms, then remove sizing tool.
14. Seat rack seal with rack by driving end of rack with suitable tool. Do not remove rack.
15. Install left tie rod and ball socket on rack and hand tighten.
16. Thread rack sleeve protector tool No. T74P-3504-J, or equivalent, over threads on right side of rack and coat sleeve with suitable lubricant.
CAUTION: Rack must not move too far from center as excessive travel may cause rack teeth to cut left inner oil seal.
17. Apply suitable lubricant to outer rack oil seal and, using suitable tool, install high pressure oil seal in rack bushing.
18. Apply suitable lubricant to short protective sleeve on rack and seal outside diameter on rack bushing.
19. Start bushing on rack with seal facing inward and pass bushing and seal over protective sleeve and into housing bore. Using Teflon(R) seal sizing
tool No. T78P-3504-M, or equivalent, apply hand pressure to rack bushing until bushing seats in gear housing. If rack bushing will not seat with
hand pressure, a 1 1/8 inch, 12 point or larger deep socket and a plastic mallet may be used to tap bushing in place.
20. Install snap ring in right end of gear housing.
21. Install right tie rod assembly. Torque both tie rod sockets simultaneously to 55-65 ft lb by holding one and turning the other.
22. Install coiled pins in sockets by lightly tapping with hammer until seated.
23. Fill yoke plug hole with 2 ounces of suitable lubricant.
24. Install yoke plug in gear housing.
25. Install yoke in gear housing.
26. Install yoke spring in yoke.
