Merkur Xr4ti L4-140 2.3L SOHC Turbo (1985)
11.
Measure and record the distance the rack extends from the pinion end of the housing. Take measurement from the edge of the housing to the end
of the rack.
12.
Mark housing in line with the blind spline on the input shaft.
13.
Remove pinion shaft dust cap.
14.
Remove pinion lower bearing bore plug.
15.
Remove pinion bearing locknuts.
16.
Remove pinion upper bearing and seal retaining snap ring.
17.
Drive end of pinion shaft out of lower bearing.
18.
Pull input shaft/pinion assembly out of the housing upper end.
19.
Push rack toward the pinion end of the housing until it bottoms in the housing.
20.
Turn rack bushing clockwise until free end of the lock wire is visible through the slot in the housing.
21.
While holding the lock wire, turn the rack bushing counterclockwise to start the wire through the slot.
22.
Continue turning the bushing to remove the lock wire through the housing slot.
23.
Pull rack from housing.
24.
If rack bushing is stuck in the housing, proceed as follows:
a. Install a tie rod and ball joint assembly.
b. Install the weight from slide hammer T50T-100-A onto the tie rod.
c. Install a flat washer and tie rod end locknut.
d. Using the slide hammer weight against the washer and locknut, pull rack bushing out of the housing.
25.
To remove rack inner seal and support ring modify a drift approximately 1.03 inch in diameter. A socket wrench and long extension will work.
Drive the ring and seal out of the rack bushing end of the cylinder.
26.
Remove pinion lower seal and bushing.
27.
Remove pinion bearing retaining snap ring.
28.
Remove pinion lower bearing.
29.
Remove seal ring from rack piston.
30.
Remove seal and bearing from pinion shaft.
31.
Remove snap ring from input shaft.
32.
Remove seal rings from valve assembly.
33.
Remove rack bushing oil seal.
ASSEMBLY
1.
Lubricate rack piston with automatic transmission fluid or power steering fluid.
2.
Install piston seal onto piston.
3.
Lubricate, then install seals onto valve assembly. Install mandrel T81P-3504-M1 or equivalent over the valve assembly. Lubricate and install seals
onto mandrel. Slide ring pusher T81P-3504-M2 or equivalent over the mandrel and push down rapidly to force the seal over the mandrel ramp into
the seal groove. Remove mandrel.
4.
Ensure seals are properly seated in their grooves.
5.
Lubricate the inside of sizing tube T81P-3504-M3 or equivalent, and slowly work the tool over the seal using a rotating motion.
6.
Install spacer T81P-3504-M4 or equivalent. The spacer will align the mandrel with the second seal groove. Repeat steps 3 through 6.
7.
Install a second spacer T81P-3504-M4 or equivalent, against the first spacer, these spacers will align the mandrel with the third seal groove.
Repeat steps 3 through 6.
8.
Remove the second spacer, turn it over and install on the shaft, opposing the first spacer. The spacers will now align the mandrel with the fourth
seal groove. Repeat steps 3 through 6. Remove mandrel and spacers.
9.
Install double-wrap snap ring into input shaft groove.
10.
Install rack bushing seal using a suitable tool with seal lip and spring facing the tool.
11.
Install rack inner seal support ring into rack cylinder.
12.
Install rack inner seal using tool No. T78P-3504-K or equivalent. The seal lip and spring must be positioned against the tool.
13.
Install pinion lower bearing.
14.
Install pinion lower bearing retaining snap ring.
15.
Install pinion bushing and lower seal.
16.
Pack rack teeth and coat yoke bearing with suitable lubricant.
17.
Position Teflon ring sizing tool T74P-3504-H or equivalent, into mouth of the rack cylinder. Lubricate tool bore and push rack through the sizing
tool into the housing. Continue pushing the rack until the piston bottoms in the housing. Remove the protective sleeve and sizing tool.
18.
Lubricate rack seal sleeve tool T74P-3504-J or equivalent and position it in the rack bushing and seal assembly.
19.
Install rack bushing with seal facing inward.
20.
Remove protective sleeve.
21.
Turn rack bushing until the lock wire hole visible through housing slot. Insert lock wire through the slot and position the bent end in the rack
bushing hole. Ensure bent end of the lock wire is fully seated in the end bushing so that it will not be distorted by the edge of the slot when
the bushing is rotated.
22.
Turn bushing clockwise one full turn until the lock wire is pulled completely into the housing. Then rotate the bushing an additional one-half turn
to position the bent end of the lock wire 180° away from the slot.
23.
Fill lock wire slot with suitable grease.
24.
Install transfer tubes.
25.
Position rack into housing until the pinion end of rack extends from the housing the distance recorded previously.
26.
Install sizing tube T81P-3504-M3 or equivalent, in top of the valve bore.
