Topaz V6-182 3.0L (1992)
10.
Ensure yoke in positioned correctly then install rack, ensuring not to scratch housing piston bore.
11.
Carefully push piston through sizing tool. Continue pushing on rack until it bottoms. Remove sizing tool.
12.
Seat rack seal with rack by driving end of rack with a drift and plastic mallet.
13.
Install lefthand tie rod hand tight to prevent potential inner seal damage due to excessive rack travel.
14.
Center rack in housing.
15.
Install rubber O-ring on aluminum rack bushing.
Fig. 30 Rack Bushing & Seal
16.
Apply power steering fluid to outer rack seal and install seal in rack bushing. Seal lip spring must face inside of bushing, Fig. 30.
17.
Install rack seal protector tool No. T81P-3504-N or equivalent over threads on righthand side of rack. apply power steering fluid to protective
sleeve.
18.
Start bushing, seal side out, on rack. Position bushing into housing. Place end plate against rack bushing.Apply hand pressure to end plate and rack
bushing until bushing seats in gear housing. If rack bushing will not seat with hand pressure, a 1 1/8 inch deep socket and a plastic mallet may be
used to tap bushing in place.
19.
Install retaining ring and remove protective sleeve.
20.
Install tie rod assemblies as previously described.
21.
Install input shaft and valve assembly.
22.
Support gear on wood block at yoke plug opening. Using a 1 1/4 bar with a flat end, flatten expansion plug until flat portion is approximately 1/2
to 3/4 of total plug diameter. Do not flatten plug completely or it may fall out.
23.
Install spring, plug and locknut. Adjust yoke plug preload as previous described.
24.
Fully extend lefthand end of rack. Apply two ounces gear lubricant to pack rack teeth. Place any remaining grease into lefthand end of gear
housing.
25.
Install bellows, breather tube and bellows clamps.
26.
Install jam nuts and tie rod ends on tie rods.
Input Shaft and Valve Assembly
Disassembly
The only serviceable component of the input shaft and valve assembly are the four plastic O-rings.
1.
Clean exterior of steering gear thoroughly.
2.
Mount gear in holding fixture tool No. D87P-3504-B or equivalent.Do not hold gear in vise.
3.
Do not remove external pressure lines unless they are leaking.
4.
Loosen yoke plug locknut to relieve preload on rack.
5.
Remove pinion bearing plug using pinion plug spanner tool No. T83P-3504-AH or equivalent.