G 2500 3/4 Ton Van V8-305 5.0L (1990)
Fig. 4 Adjuster plug removal
1.
Install connectors using valve connector installer tool J-6217 or equivalent, Fig. 8.
2.
Lubricate 24 balls with power steering fluid, then install alternately by color into rack piston, Fig. 9. Use ball retainer tool J-21552 or equivalent,
Fig. 2, to hold balls inside.
3.
Install balls in ball guide alternately by color, retain in guide with petroleum jelly. Fig. 10.
4.
Connect ball guide, clamp and screws to rack piston.
5.
Lubricate stub shaft, valve spool and seals with power steering fluid, then install into valve body.
6.
Connect valve body, seal, worm shaft, races and roller bearing.
7.
Install seal on adjuster plug, then needle bearing in adjuster plug using J-8524-1 and J-7079-2 or equivalent. Fig. 11.
8.
Install seal, washer and retaining ring in adjuster plug. Retainer projections must not extend beyond washer when retainer ring is seated.
Washer must rotate freely.
9.
Install worm shaft and valve assembly into gear housing.
10.
Install adjuster plug into gear housing using spanner wrench tool J-7624 or equivalent, Fig. 4.
System Flushing
1.
Raise front end of vehicle off ground until wheels are free to turn.
2.
Remove fluid return line at pump reservoir inlet connector, then plug inlet connector port on pump reservoir.
3.
Position fluid return line in large container.
4.
While a second person fills reservoir with power steering fluid, start engine at idle.
5.
Turn steering wheel from stop to stop. Do not hold wheel against stops while flushing system. Holding steering wheel against stops will cause
high system pressure, overheating and damage to pump and/or gear.
6.
Continue draining until all old fluid is cleared from power steering system. The addition of approximately one quart of new fluid will be required
to flush system.
7.
Unplug pump reservoir inlet and reconnect return line.
8.
Turn engine Off, and fill reservoir to Full Cold mark.
9.
Bleed system as outlined under SYSTEM BLEEDING.
System Bleeding
If system has been serviced, an accurate fluid level reading cannot be obtained unless air is bled from system. Any air in the system may cause pump
cavitation noise and may cause pump damage over time.
1.
With engine off, front wheels off ground and wheels turned to far left, add power steering fluid to FULL COLD mark.
2.
Bleed system by turning wheels several times from side to side without hitting stops. Add fluid if necessary.
3.
Fluid with air has a light tan appearance. Air must be removed before normal steering can be obtained.
4.
Start engine, recheck fluid level and add if necessary.
5.
Return wheels to center position. Lower vehicle to ground and continue running engine for 2-3 minutes.
6.
Road test vehicle to ensure steering functions properly and is free from noise. check fluid level and add if necessary.
Service Procedures
To prevent damage to the rack and pinion boot seal during removal, the following should be noted. Slide the small end of the boot toward the
rack until the groove is exposed. Place a small rubber band in the groove, then slide the small end of the boot over the rubber band and off the
threaded end of the tie rod.
Lip seals, which seal rotating shafts, require special treatment. This type of seal is used on the steering gear at the pinion shaft and on the pump drive
shaft. When a leak occurs in these areas, always inspect and thoroughly clean sealing surface before replacing. Replace seals only if severe pitting is
found. If lip seal contact zone corrosion is slight, clean the surface of the shaft with crocus cloth. Replace only if the leakage cannot be stopped by
smoothing with crocus cloth first.
