626 L4-2000 1998cc (1983)
Fig. 14 Disassembled view of power steering gear. 1984-87 626
Gear Disassembly
1.
Drain lubricant from gear, then secure gear in a suitable vise.
2.
Remove tie rod ends, then the boot bands and wires and the boots, Fig. 14.
3.
Remove pinion plug and locknut from bottom of housing.
4.
Remove tie rods and spring pins. Mounting toothed portion of rack in a vise will cause the rack to push spring pins partially out of pin
holes. The pins can then be pulled out with pliers.
5.
Remove rack bushing assembly.
6.
Remove pressure and return lines from housing.
7.
Remove locknut, yoke plug, spring and rack support.
8.
Remove dust cover and snap ring.
9.
Remove control valve, oil seal and bearing assembly using a suitable press.
10.
Remove oil seal and bearing from control valve assembly.
11.
Remove rack oil seal as follows:
a. Install rack protector No. 49 G030 595 or equivalent to rack, then remove rack bushing assembly.
b. Remove steering rack using oil seal repair No. 49 G030 665 or equivalent. The oil seal can now be removed with rack assembly.
13.
On all models, install rack protector No. 49 G030 595 or equivalent and remove rack.
14.
Remove seal ring from rack, then tap bearing out of bottom of housing.
15.
Remove mounting brackets and rubber mounts, then the gear housing.
Gear Assembly
1.
Before assembly, the following parts should be coated or packed with lithium base grease or equivalent:
a. Pinion teeth.
b. Pinon installation point of gear housing.
c. Rack support sliding and rear surfaces.
d. Ball joints and boot inner surfaces.
2.
Apply clean transmission fluid to pinion seal ring, then install rack into housing with rack protector installed.
3.
Apply suitable sealant to threads of rack bushing oil seal and the bushing assembly, then install oil seal and bushing.
4.
Apply clean transmission fluid to control valve, bearing and oil seal and install them into housing. Press oil seal in until it reaches snap ring groove
and ensure rack and pinion gear are properly meshed.
5.
Install snap ring and dust cover.
6.
Install rack support, spring, yoke plug and locknut.
7.
Secure toothed portion of rack in a vise, then install tie rods and torque to 87 ft.lbs.
8.
Install new spring pins.
9.
Install bearing and torque locknut to 29-36 ft.lbs.
10.
Apply suitable sealant to pinion plug, then install the plug and torque to 33-40 ft.lbs.
11.
Torque yoke plug to 130 inch lbs., then loosen it. Repeat this sequence three times.
12.
Torque yoke plug to 48 inch lbs., then back it off 45° and tighten the locknut.
13.
Measure rotational torque of pinion using a spring gauge and tool No. 40 0180 510B or equivalent. Torque should measure 18-42 ounces.
14.
Install pressure and return lines and the pressure switch.
15.
Install boots with new wires. Wrap wires twice around boots and twist ends 4-5 times around, then install bands on opposite end of boots.
16.
Install tie rod ends. Exposed portion of threads should measure .47 inch.
