Alliance/Encore L4-1721cc 105 CID (1985)
Fig. 18 Removing pinion bearing.
b. Remove tool and bearing using slide hammer tool No. T59L-100-B, Fig. 18.
16.
Push in right side of rack until it bottoms, then install rack bushing locking tool No. T77P-3504-A so the two drive tabs engage slots in end plate.
17.
Rotate tool in a clockwise direction until end of retainer lock wire is visible in the slot, then remove lock wire using suitable tool.
18.
Rotate rack until teeth face upward, then pull rack end plate, aluminum rack bushing and rack assembly from right side of housing.
19.
Remove inner rack oil seal using expander tool No. AMC-3504-C and slide hammer tool No. T59L-100-B. Inner rack oil seal contains a plastic
ring that may separate during removal. Ensure that all parts of seal are removed from inside of housing.
Fig. 19 Removing rack bushing seal.
20.
Install rack bushing into rack bushing holder tool No. T81P-3504-D, then remove seal from bushing using tools No. AMC-3504-C and No.
T59L-100-B, Fig. 19.
21.
Remove O-ring from rack bushing.
22.
Remove plastic piston ring from rack piston, then the rubber O-ring from rack piston.
Assembly
The following procedure applies to power steering gear only. Manual steering gears are not serviceable and should be replaced as a unit.
1.
Lubricate inner rack oil seal with power steering fluid, then install seal in right end of rack housing using sizing tool No. T81P-3504-K and
installer tool No. T81P-3504-C. Tap tool handle with plastic hammer to seat seal.
2.
Install rubber O-ring in rack groove, then place plastic ring on tool No. T81P-3504-L.
3.
Position tool on rack, then slide plastic O-ring over the rubber O-ring using tool No. T81P-3504-M2.
4.
Coat rack teeth and yoke bearing area with suitable lubricant.
5.
Install protective sleeve tool No. AMC-3504-E over rack and sizing tool No. T81P-3504-K into rack housing, then lubricate sizing tool with
power steering fluid and push rack into housing until leading edge of rack engages internal oil seal.
6.
Install left tie rod assembly hand tight to prevent rack teeth from damaging the internal oil seal.
7.
Install bushing and seal on outer rack oil seal, then the rubber O-ring on rack bushing.
8.
Install rack protective sleeve tool No. T81P-3504-N on right side of rack.
9.
Lubricate protective sleeve and rack bushing with power steering fluid, then install bushing into the housing bore.
10.
Install housing end plate on rack and position against rack bushing.
11.
Seat rack bushing in housing using lock ring tool No. T77P-3504-A. It may be necessary to tap lock ring tool with plastic hammer to move
bushing in place.
12.
Turn lock ring until the lock ring retainer hole is visible, then install lock ring wire and rotate retainer clockwise until wire end is completely
enclosed.
13.
Install pinion bearing in housing. Use a plastic mallet to tap bearing into housing bore.
14.
Grease pinion bushing and apply power steering fluid to oil seal.
15.
Position seal on installation tool No. T81P-3504-F, then using a plastic mallet, tap the seal into housing and seat against shoulder.
