omotive rcia) Steering Systems HF Steering Gear service Manual HE64 SERIESDefinitions NOTE: A NOTE gives key information to make a procedure ezsier or quicker to follow. CAUTION: A CAUTION refers to those procedures that must be followed to avoid danvage (0 a steering component or the gear. WARNING: A WARNING REFERS TO THOSE PROCEDURES THAT MUST BE FOLLOWED FOR THE SAFETY OF THE DRIVER AND THE PERSON INSPECTING OR REPAIRING THE GEAR. The product reprosantad horcin is provested by United Sletes patent No. 3, U47, 087 ‘STRIVING. 1095Table of Contents HEG4 Design Features and Phancam View Definitions and Patents Intmneuetian HEA Hiciaulic Fd Powe Hlstraton Valve Hydraulic Fluid Flaw Wlustratian Ht General Design end Operation ‘Troubleshooting Information Troubleshooting Guide Repairs and Adustments on Vehicle —The Sector Shait Trunnion Cover Seal —The Worn (trput) Shaft Seat —Worm Shalt, Valve Thrust Bearing Pralcad Adjusiment —Poppet Valve Adjustment —Croas Shaft or Sector Shaft Adjustment Torque Chart Tuils and Materials Mequired for Servicing HF64 Exploded Assembly View-1ypical Disassombly . Inspection ‘Assembly final Adustmonts Hydraulic Fluid Filing and Air Pleading the Systam WARNINGS lu Phoner Steerinn Geer Operation Steering System Micintenance Tins Page Inside Front Cover 2A and 213 2 33 28 2 88 53 ft CT WARNING: ALL STEERING MECHANISMS ARE LIFE AND LIMB ITEMS, AS SUCH, IT IS IMPERATIVE THAT THE INSTRUCTIONS IN THIS BOOKLET ARE FOLLOWED T0 THE LETTER. FAILURE TO OBSERVE THE PROCEDURES SET QUT IN THIS PAMPHLET MAY RESULT IN LOSS OF STEERING,Introduetion Service Manual for Model HFB4 This service marwal has ane purpose: 10 guide you in maintaining, troubleshooting anc servicing the HF6¢ Hydrepawer” integral power stearing goat. Material in this manual is organized so you can work an the HE64 and get results without wasting ‘ime or being cenfusad. To get these results, you should review the vuntunts uf this rmarwa before yuu begin any warc an the HEEB, The section uf this mental on General Oasiqn and Uperation, teats the maior parts of the HFG and expleins How thoy funetion together. The knowledge you auguire fram reviewing ‘this section should exsist you in-soing your steering problem. This manuel also contains truubleshooting information and checklists, With them, yuu van diagnose a ste ing problem without removing the HFG4 from the vehele. (f you must sorvicg the HF64, the chocklits will help you to determine where the problem may be. The three-culunin format af the Repairs, Adjustments, Disassembly, Inypection and Assembly sestors wil meke it easier for yuu to service the HFEA. Column 1 gies a biel key for ezeh procedure, Column 2 uxalzins in darail the procogure you should follow, Column 3 illustrates this proveduie with phulogrephs. Pay special attention 10 the notes, ceutions end warnings. AA toldout page with the serne typical HFA exploded assembly view on both sides is provided in this manuel. The companent part names and item numbers essigned on tis explnded assembly view correspond with names and item numbers in parentheses! used in tho diseesemtly, essambly and othor procedures sot forth in this manuel. Whon this exploded assembly wew paye 1s lolded oul, you can easiy idemify components ard locate their relative pnsitian on the exploded assernhly view as you folly the disessambly, assembly and other procedures As you gain experiance in servicing the HFO4 you may find that some inforrtion in is manual caud be clearer and mere eamplete. IF so, let us kntww abnut it. Dont try 19 seeond gunss the manual; if you ere stuck, conto! us, Servicing the HFG4 should be a safe and productive procedureHF64 Hydraulic Fluid Flow Illustration ‘STEERING WHEEL INPUT (Clockwise Rotation} STEERING WHEEL INPUT (Coumter-Clckuvise Rotation) SS jn GE surrey rressune RETURN OM FLOWValve Hydraulic Fluid Flow Illustration > Fluo FROM PUNE crerre> DISPLAYED FLUID FROM GYLINDER SHAFT AND $P00L move FIG, B VALVE POSITION AND FLUID FLOW FOR FIGHT TURNING FROM CYLINDER “to cvumner INLET PORT (FROW HYDRAULIC PUNE} RELOADED SPAINGS PLUNGERS: SHAFT AND. ‘SPOOL CENTERED VALVE SPOOL VALE Housing —™” FIG. A 0 power evunnen 7) j TO Powen CYLINDER, NEUTRAL VALVE FOSITION AND FLUID FLOW OUTLET PORT {FOR RETURN TO RESERVOIR SHAFT AND SPOOL oven >> i FIG. C VALVE POSITION AND FLUID FLOW J FOR LEFT TURNING ro cvunoen—~ FROM CYUNDERHF64: General Design and Operation Dasign Integral Power Steering The HF power steering gear i ane of the Ress tery oF integral hydraulic power steering gears, Integral hydraulic power steering means that The gear box ceantains a manual steéting mechanism, a hydroulic contra valve, anda hyrtaulic ower eviinder, all in a single, compact package Linear Control Valve The linear coniral valve canines simplicity of cunsructiun with desirable ftrformewce characteristics. ‘The speed al which tho drivar can tunt the slwaring vw! with power asst is dependent upon the yup flow (neesurad in gallons per niule—yorr ot Lessin) directed tw 2 cylinder cavily. The pressure (measured in pounds per square incl—psi or but} required for the year W sluer the vehicle is created by the power steering pump to overeome resistence at the steered whee’, The canirdl valve senses these requiramants and directs fuid 10 the syinéer cavity at the proper flow rate and pressure, Pressure Means Work, Flow Means Speed The higher pressure a gear can withstard, the more work it can perform, The HEO4 can steer a vehicle wit 9 trant snd weight raring of about 12,000 pounds 5433 Kgl through a surn at lw vehicle seed and engine idle, As the chivar turns the steoring wheel fester ur slower, mare or less dud will be required by the goor in one minute, For the HFBS, imaximurn queraing prossury is 1750 PSI (120.7 BARI, The absolute maxinurt flow rate is 8 GPM (30 Litersinin.. The vehicle manufactur’ specifizatiors: must be referred to for the maximum flaw rate {GPM or Litersimnin.t as it will be ower On pariculr AFB stearing gear cgplvations, NOTE: The recommended nninimum flow at 1% hand wheel ‘tums /second must be na less than 3.2 gpm (12.1 LitersiMin4. If the HFG4 steering gear is controling an auxiliary cylinder, incraased minimum flaw is required based on the size of the auxiliary cylindar and the vehicle's steering geometry. Operation What Happens During 2 Steering Maneuver When the driver turns the steering wheel, he transmits rotaional force frum the stvering wheel 1v the steering geet worrn Cingut! shart, In resporso to this rotational free, the worm shall, acting ‘through the recirculating melanin, ties tu move Ue rack piston aia through the year housing eylinder bora The rack piston’ axial wovervent is resisted by ils engagement te the sector slall, whith s connected by irkage ta tho slevred wel, Baceuse of this resistance, an axiel movernent is then tuansrittad to the worm shait & valve spodl, overcoming the hydraulic & spring fotos that comer the contro vale, ‘thereby aotusting tha control valva Pressurized fluid, dirscted by the contral velve, assists in moving the rack piston axially ough the cylinder bore, The rack piston then tuins the sector sha’t to steer the vehicle Shock Loads to the Gear If the steered wheols rapeive a shock loed, the shook forces are tensmittad lnough the sector shatt, 10 the rack piston, and onta the worm shat, The internal geometry of the steering geer causes the conn! vee to sen high pressure fhid th the enreect cylinder cavity 19 resist thn stock forces. By absorbing the shoe forces hydraulcelly, the steering gear prevents objacionalle kien at the steering whee. Unloading (Poppet) Valves The HFG4 gears are equipped with two uninding vals, one al each end uf the rack pistan travel. One vale or the othe, depending ur Une direction of turn, will tsa as the steered wheels approach the ate slaps (ich must be sel ancording to manufaciurur's specification), The trigued valve veduces pressure ine gear and hes Ww reduce heat generated ay the pump. At the some time, the valves algo reduce foreas on the steer linkage,Troubleshooting Information Preliminary Checks When @ cisiurier comes 10 you wih & problen related to bis ‘wuck’s steering, you can save a lot of time and wrark if yuu ‘ist verily the problem. Make suce youre both talking the same language about the seme prohiam, If he seys the vuck’s hard 10 steat, find out exact what he meats, Is it hard stewing into @ night o leit tun? Only when turning the steering whee while the truck is siting sil? Is there any interment power steering? Ur is there no puwer assist at all? iat all possble, and ifs safe to do so, test chive the tusk Ui you're rot fernlcr with tho rig, atthe eustornar dive whie you sit Ueside lim. Take hold of the wheel whie he chives to got feel fur the prnblem te’ talking about, Since most of his driving wil be with his tuck heuling @ load, arrange for & load i une is required to reproduce the sieeing problem, Ohee you've determined the problem and its symgtoms, don't jump right in tw war he steering gear or pump apart. kt mast ‘cases, i fact, the pear should he the last camaanent you chock, Thora are many ather componenis in the steering system that vould be causing the probem (sea FIG, 1), These you should check fist TYPICAL STecu: SvETIMN Figure 1 Bagh, then, by closking tie stoored wheels: make sure thel the tikes ere al correct pressure and equal al eround, that thoy fare properly siad, and thal they ara nai worn or damaged Nex: have the frant-one alignment chacked and look for abnormel looseness ar tightness in the steering linkage, ball joins, ané king pins. ‘A service replacement hose of tui line may be misrnuted or thay be ton small in dameter, or iL may ba rastrcted in samo sine way. Neraure any hose that i Kinked ur bunt sharply Reptace any fuses that are not the same as origi eninment, Continue by shecking the power steering il jeservoir ia make sure thal cil is up to the correst level. Also, chack the pump rive bol, if one is used, tm see 4 iw slipping, The belt may be tight, but it may also he glazed, and a sipping belt doesn't always squeal. If you adjust the belt, chack the sgusfietions ‘These are just some ot the checks you should make bafare you turn to the steering gear or pump. The Troublashucring Guide «an pages & thru 17 explais what ta diagnose for a paricalar steering problem, Mateh the trouble symptom against the chart and follow the rezommended troubleshooting sequence. ong st will must likely save you tie and may prevent urmexessary repeirs wd cuss Hydraulic Tests I the chicks deseribad aheve all prove satisfactory, it is pesabbs that Ure cause of the steering problem can by raved iu a lack af pressure cr insufficient finw, In tis case, you mey have ta do more detailed troubleshooting thet involves conducting hyuaulic tess. Preparation for Hydraulic Tests Tu conduct the following hydraulic tests, first install a flew miter. prrssire gage an toad (shut ofl value in the tid supaly fine tn the stocring gear, as huiceted by the instructions that come with the flow meter. Steenng system analyzers are available with the 3 urits integral, Place @ thorriamioter in tho reservair (FIG. 2}, You musi use @ flow meter, anu it is recarimesiod that you use @ themamete, il 'you are to troubleshoot she hycraulc system acsurtely. THERMOMETER ees eee Lean ISHLTOFE| 23 ye in| Figura?Start tho cnginy and warm the hydtaulle eystom up by partially using the load vale until the pressure gaye reeds 1000 ps 169.0 Ber), Whan the Thid temperature, as indicated on the therinomster, reaches between 125°F (51.7% end 135°% 187.2°C), open the loed valve, The system is warmed up, and ‘you can conduct the tests. CAUTION: Do not close the load valve completely and leave it closed, or you may damage the pump. At no time alow fluid temperature to exceed 180° (822°C). Run all the tests at the prescribed temperature range of 125°F (51.7°C-135°F (67.2°C). Power Steering Pump Pressure Test ‘With the engine ifiag, cose the toad value and cea the pressure gage. If the pressure reads below the minimunt spetifed by the pump manufaciurcy, copar or reslace the pump. CAUTION: Do not keep the load valve closed for longer than 6 seconds to avoid damaging the pump. Closing the load valve causes the pump to operate at relief pressure ‘and the fluid temperature to increase rapidly. Allow fluid to cool to between 125% (51.7°C) and 136 °° 157.2°C) before you resume with the other tests, Power Steering Pump Flow Test WARNING: MAXIMUM FLOW RATE FOR THE PARTICULAR HFG4 STEERING GEAR SYSTEM AS SPECIFIED BY THE VEHICLE MANUFACTURER MUST NOT BE EXCEEDED. EXCESSIVE FLOW CAN CAUSE DAMAGE TO INTERNAL PARTS OF THE STEERING GEAR, WHICH COULD RESULT IN A LOSS OF POWER STEERING NOTE: 'f methods of checking flow rate are provided by the vehicle manufacturer, you should follow those instructions rather than the procedure described below. With the engine icing end the fluid ermpereture between 125° (1.7°C) end 1254 {57.2°C!, check the pump manufacturer's spuivations for Mow rate. Conyare Use specications with the flowy ete on the Mow meter. Now, filly nse the Inedl valve until the pressure gage registers the pensnure at which the pump is relieving. When qump rot is reeched, flow rate must te ra. IMMEDIATELY OPEN THE LOAD VALVE. The flow rato must instanly return to the suiginal reauing. 1F this vate: dues not retun fnmedkately, the sung is malfunctioning, whist wan result in intermitten powet ass Now, set the engine nt gaverned tari, and fully elase the load valve agatn unl puma ceo is reached. At oump relief, the flow rae must be zera. IMMEDIATELY OPEN THE LOAD VALVE, Te flaw rate must instarly return to the originel reaing, II this rate does not reurn inmediately, the pum is malfunctioning, which can result in inturnittan, powar assis NOTE: Conduct the pump flow test once at idle rpm and ‘three times at governed pm. CAUTION: Do not allow the fluid temperature to exceed 180°F (82.2°C), Run each phase of this test between ‘25°F (51.7°C) and 135°F (57.2°C). Steering Gear Internal Leakage Test To test the steering gear for intornl fnakaga, you must fist prevent aperstion nf the gea's intemal unloaing fpopact} valvas, This will allow full pump relief pressure 10 develop. To prevert aparatian of the poppers, place an unhardencs stcel spacer Dock, avout 1 inch thick anc lung enough ww kegs your fingors clr, between the ade and stop et one whee! Inee 16. 9) Figure 9 With the fluid temperature hetiwnen 12B°F 151.7%C) and 196° (572°C), ura the steering wheel uit the axle stops botta wn ‘the spaner block |FIG. 3) CAUTION: When running this test, do not hold the steering whee! in the full turn position for longer than 5 to 10 seconds at a time to avoid damaging the puma. WARNING: KEEP YOUR FINGERS CLEAR OF THE AXLE STOPS ANO SPACER BLOCK DURING THIS TEST. MAKE SURE THAT THE SPACER BLOCK CONTACTS THE AXLE STOP SQUARELY. CONTACT THAT IS NOT SQUARE COULD BREAK THE AXLE STOPS OR DANGEROUSLY THROW OR EJECT THE SPACER BLOCK Apply 20 ts. 1.7. KG) w the rin of the steering wheel during this test tv be sure that the steering gear cunral value is uly closed, The pressure gaye should now read punnp relief pressure, es noted during the pump pressure test. You an now road stuoting goor internal leakago on the flew motor. Accaptable internal leakage ean range fram 0 to 1.6 gpm 1.7 Liters/Min J. Fapeet this west for the oppesite direction of turn IH internal leakage is greater than 4,6 gor (5.7 Liters!Min| and there is nu euxiliery hydraulic cylinder in the system, repair the gear. I the mtornal leakage is groator than 1.6 gom [6.7isin.) and there is an ausiliary hycrauls eyindar in Wie disconnected lines to prevent drainage. Repeet the internal system, convuted by the HFD4 geer, isolate the euxilery lenkage test. If the internal leakage ts greeter then 1.5 gpm Grlinder from tie system by disconnecting the auxiiary cylinder (5.7 LitarsMin.) repair thu HTB! ese. If itis less than 1, gom hydraulic Ves at the 84 unit's avxliary ports. Plug thove (6.7 NitessiMin.) repait the auxitary oytnder, ports with suitable pressure plugs or caps and plug the Troubleshooting Guide 1 Normal Noises * You or the driver may hear a hissing nuise fram the control velve when it is actuated during a steering maneuver © You or the criver may heer a nuise as filid bypasses through the pont i full tur. © You or the driver may hear a raise from the system relief valve when itis required 10 actuate. © You oF the tkiver may haar pump grow! fram somy tyges of power sceering pumps Il. Abnormal Noises © If the power staering pump is belt driven, 2 squealing noise may indicate that the bells shoul bo tightened or rapacod ® Acicking anise heard during a tum, or when changing dirsctione, may indzete that sume compgient is Inase and shilling unuer luad, © A chenge in the nownal nuise of the pump rray indicate that at has been induced tio the system or that fluid level i low, UL Possible Steering Problems and Causes Road Wander Tie pressure invert or uneque! left to right ‘© Campanents n stecring Unkoge luose or worn IStaeting wheel 10 roed wheel ‘Wheel bearings improperly adjusted ar worn Frant end alignment aut of specification. Dry fifth wheel oF poor finsh on fifth whee! or trailor plate. © Steering gear maunting bolts loose on frame © Steering gear improperly adjusted © Looseness it rear axle assemblies of tailor bogiesNo Recovery © Tire pressure nw © Front end eompananis binding * Front end alignment insorrest © Tight ont axe king pins © Dry fifth wheel or gour Sst un filly wheel or usin plete * Steering catuma binding # Pup tlow insulfiieot Steering gear improperiy adjusted © Steeiing gear conta vlve spool sticking Shimmy © Baul wort) unevenly worn Lies © Iimprapery mounted tre or wheel © Wheel bearings improperly adjusted or warn © Components steering Inkage loase or warn © Wheels or brake drums out of ban: © Front and aliyimet jacurect © Air iy the hydeaulin system External il Leakage © Finding the location of leak may be dilficull, since ull mey run away tom leak source, tte fitings, hoses, pump, oF year te e low paint on the gear or chassis, © Aloak fram the vert plug at the side cuverinccstes failure uf the sustur shall oi sea inside the side cover Overstesring or Darting © Diy Tilth wheel or poor linsh on fifth wheel or trailer plate * Frort ond cumpunarits binding oF Loose Siesrng colunm binding © Sinering gear improperly adjusted Sreering gene canal valve span! sticking Heer axle mounts rear steer High Steeving Effort in One Direction © Linequal tire pressure Vehicle averloated Iradequete hycraule system prescure Excessive internal loakago in one diraction of turn only verify with intarta leakage rest! High Steering Effort in Both Directions © Low tire pressure © Vehicle overloaded© Low hysraulc. tid fovel © Low pressure or flow ftom pum © Comnorerts of steering system binding © Resiretion in return tine, or fine too small in diameter © Exuessive inlommal leakage Wary with internal leakage test * Oversze Tres icheck menulactare's suecficctans) Lost Motion (Lesh) at the Steering Wheel © Steering whoel loose on the shalt © Loose connection between the steering gear, intermediate culun, ard steering ealuren © Stouring gear lone on trame * Piiman arm loose cn outgul shall © Components in steering linkage lnase or wa © Stoaring gear improperly adjusiod Excessive Heat [150 °F (65.6°C) Over Ambient! © Facassive ump flow © Vell overloaded © Undersiaee replacement hose or ine © Hestrioted hose ur tine that Is kinked ar severely bent or internally blucket © festicted recentering nt geer valve caused by column bint oF side lone an she input stall © Pornet no: adjstedpronerly © Prolonged stationery otic npnratinn WARNING: IF THE HYDRAULIC SYSTEM FLUID BECOMES OVERHEATED, IT GAN CAUSE THE SEALS IN THE STEERING GEAR AND PUMP TO SHRINK, HARDEN, OR CRACK AND LOSE THEIR SEALING ABIL/TY.Repairs and Adjustments on Vehicle ‘Wher you hewe conducted the checks and tests described in the troubleshooting sections, you may find it necessaiy to repair or adust the steering gear. Singe removing the gear fror the vehicle 8 usuelly dffcult and time-consuming, you vill probably find it easier to pertowrn the talowing repairs anc adustmanis wah the gear on the vehicle. The phatagraghs in th seein shaw a gear rmauntad an a mock-ap frame for clearer illustration remove pitman i arm NOTE WARNING CAUTION Temove protector 1,2 seal dean sector 13 shaft v The Sector Shaft Trunnion Cover Seal i a leak is detected! in the trunnion cover area, on mary HF84 insialetons, you nan remave tha ‘runnin cover to gain access to she sector shah seal paskage, while the steering gear is nn the vehicle. Fist remave pitman arr rat and bolt a the sector shaft nur (580 and lnckweshor (5461 tnd then the pitman arm from the sector salt Ia6), SEF FIGURES 4 & 6. Check the racial snsiion af the pitman arm to the sector shel aiar 10 removal of pita ser, Ald Lining marks vo the arm and shaft if nevassary Lo ensure sntract algnmant at ruassunibiy NOTE: A chisel will help you loosen the pinch bolt type pitman arm. Use only a guller if you cannot remove the pitman arm with your hands. WARNING: WHEN USING A CHISEL TO SPREAD THE PITMAN ARM ROSS IN ORDER TQ LOOSEN THE PITMAN ARM FOR REMOVAL FROM THE SHAFT, MAINTAIN A FIRM GRIP ON THE CHISEL AT ALL TIMES. FAILURE TO 06 THIS MAY RESULT IN THE CHISEL FLYING LOOSE WHICH COULD CAUSE AN INJURY, NEVER LEAVE THE CHISEL WEDGED IN THE PITMAN ARM BOSS. IF YOU CANNOT REMOVE THE PITMAN ARM FROM ‘THE SHAFT WITH A CHISEL AND YOUR HANDS, REMOVE THE CHISEL FROM THE PITMAN ARM AND USE A PULLER ONLY TO REMOVE THE PITMAN ARM. CAUTION: Do not use a hammer on the hitman arm to remove it from sector shaft as intemal damage to steering gear could result. Remove protector seal (B31. SEE FIGURE 6. Clear the sacior shalt (48) with @ fine grave of emery paper. Re sur to remove any paint, SEE FIBURE 7 Figure 6 figure |remove trunnion 1.6 cover and seal package clean and inspect 1.5 trunnion cover WARNING install new 16 Tetlon washer and seal package CAUTION install new ta seal ring WARNING tape sector 18 shaft NOTE “Leton is 9 roysiered adem Nec, remove the four trunnion sover sorews (GIA), and trunnion cover {62}, SEC FIGURE B. A 14 inch Allen scoker required. Be prepared for {hid loss. Thea remove and dscard he sector shoftsenl package consisting of the two-piece sector stoft seal (43), the "Teflon backup washer 142), and the trunrinn cover see sing I61), SEE FIGURE 9 Clean the tunnion cover |B with potroloum based solvent and inspect the seal cavity and seeling tate for nicks or corrsia, Replace rhe trunnion cover with @ ew one if these conditions exit WARNING: SINCE THEY ARE FLAMMABLE, BE EXTREMELY CAREFUL WHEN USING ANY SOLVENT, EVEN A SMALL EXPLOSION OR FIRE GOULD CAUSE INJURY OR DEATH. Plase the trunnion cover (2) on a clean work surface. Install a new Teflon washer (42) then a new two pizce seal 143], or the latest new service two piece seal (42/43) that has the Teflon washer hntegrel tu it, Soo alternate sores sorstructin on extloded assembly review. SEE FIGURE 10. CAUTION: Be sure that a separate Teflon westor (42) ie not used with tho service two piece seal (42/43) that has the Teflon washer integral to it Grease the mew trunnion cover seal ring [511 and install into the caver ring groove WARNING: THE WORDS “OIL SIDE” MUST BE VISIBLE ON THE SEAL AFTER IT 18 IN PLACE IN TRUNNION COVER. THE SEAL WILL WOT FUNCTION IF THE SEAL IS REVERSED AND A LOSS OF POWER STEERING ASSIST MAY OCCUR. SEE FIGURE 11 Cover the serrations of the sector shaft {4B} with tape to avail damaging the seals during instalation. SEE FIGURE 12. NOTE: Use only one layer of tape. sf DuPont Coqination figure 12install trunnion cover and scraws assemble protector seal install pitman aim WARNING install sector shaft rut and washer or pitman arm bolt and nut CAUTION fill and bleed system “4 oF 4.0 1M ase 118 Agply clean high emperature grease per Noss specification 045231, Mobil Temp. 1 u 2, at equivalent to sector shat seal area and nstall the trunnion cover 1b)! and tour trunnion Screws (5A), Torque sorews wo 13-28 ft ths, (BST N ml if dry ar 19-16 ft Ibs, (1222 Nb lubrisared. SEF FIGURES 13, 14, Remove tape ‘fom seesnr shat Figure 14 Pack clean high temperature industriel greese per Nass specification 045231, Mabil Temp. 1 ar 2 or ‘equivalent to protector seal (63) and install protector seal lo sector shaft 148) and trunnion cover '62), SEE FIGURE 15, Reconnect the gitman arm, making sure the tinny snark un the piunan arn agus wih the timing snark un the secter shaft. SEC FIGURE 18 WARNING: WHEN USING A CHISEL TD ‘SPREAD THE PITMAN ARM BOSS FOR ASSEMBLY ONTO THE SECTOR SHAFT (48), MAINTAIN A FIRM GRIP OW THE CHISEL AT ‘ALL TIMES. FAILURE TO 00 THIS MAY RESULT IN THE CHISEL FLYING LOOSE WHICH COULD CAUSE AN INJURY. NEVER LEAVE THE CHISEL WEDGED IN THE PITMAN ARM BUSS, If required assemble the sector shaf: washer (548) and nur (54C). Tomue nut to 475-H00 fr. ths, 1644.670 Nm). H rcquired assemble the piunan arn daryp nat and oll, Turque bul eo 380-420 ft hs. 1615-669 N mb if dey and Unploted, Torque bolt to 900920 ft, ts, 1207-404 Nm} it bolt & lubricated a glated, SEE HIGURE 17. CAUTION: Be sure there is no spreeding wedge left in the gitrian arm boss before torquing pitman arm clamp boit. Refore operating the steering gear, fill the system with the recommended fluid and bleed air from the system hy follnwing the Filing and. Air Blueding instructions on page 63 figure 17temove input eoupling: clean input shaft WARNING remove and plug the return fine remove retaining ring apply air pressure to port WARNING 21 22 23 24 The Worm (Input) Shaft Seal tf there is a leak in the worm shaft seal, you can usualy rplace tha input shatt soal assembly (4) vit the gear on the vehide, Start by rermoving the ingut cauplng per the vehicle ranuitactuers instructions, SEC FIGURE 18. Mamave seal protector (1) and clean lie arca around the worm shaft (258) with » fino yrade of emary agp SEE HGURE 19, WARNING: 00 NOT DRIVE OR PRY COUPLING FROM SHAFT, INTERNAL DAMAGE TO THE ‘STEERING GEAR CAN RESULT. IF COUPLING {8 TIGHT, INSERT SCREWDRIVER INTO SLOT ‘TO RELEASE, Figure 18 K BX is Figure 19 Alomave ard plug the retum fine in tho upper cover I7|, SEE FIGURE 29, Ramove the seel retaining ring (2| from the upper cover (7), SEE FIGURE 21 Hold @ shoo rag over the worm shell (25D) and ‘anny shop ar pressure 10 the return port in tupner eavnr (7|, SEE FIGURE 22. WARNING: WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA OR OTHER MAXIMUM AIR PRESSURE REQUIREMENTS, Figure 22remove seal and washer instal seal package ‘grease worm shaft anti protector seal assemble protector seal reconnect line reconnect input voupiing WARNING fill and bleed system 25 27 28 29 210 an Ihe air pressure will force the two-piece input shaft seal If] and the stool backup wveshor {3) ta flop our nf the gear, ancl some thud wl teak from the goar. Diseard! tha twn.piacs seal Disconnect the shop ai as scon as the seal assembly is out. SEE FIGURE 23 lone the worm shaft srraions. Asseirble new seal (d)onta wom she (758) and into wane raver {7} with seal lip fing the wuper cover bearing (5. Remove tape, Arcily the special high temperature industrial groase por Rows specification 048231, Movil emp, | 0: 207 equivalent to ade up washer (3) an inal i, against seal (4). Assemble rete ning ring (2). SEE HISURE 28 and 25, Aaply inora of the spocil grease in tho seal arse ‘i worm shelt 125) and to the new protectar seal (1], SEE FIGURE 265 Asgermnle new protector seal |) unt wor shaft (9501 and upper caver (71, SEE FIGURE 27 Remave the plug and reeannaes te eeturn fine Feconaest the input enupling to worm shaft 1258). If the ingut couuling rate assembly sives fro uf tho forrala ond during aseombiy, realign Ue ting marks to ensure proper phasing of the Ujoinis, Refer to vehicle manufacturer far ‘ecommended torque, Reconnect the return line WARNING: MISTIMED U-JOINTS CAN RESULT IN A BUMPY SENSATION AT THE STEERING WHEEL AND POSSIBLY AFFECT STEERING CONTROL. Boforo quurating lie stozring gua, fill the yet ‘with tre recommended fluid and bleed eir trom the system hy follwing the Filing and Ai Bleeding instructions on pege $2 Figure 27Adjustments You nan meke three adjustments to the gear while it i mounted on the vehicle; the worm sheft ard volve thrust beeriny preluad adjustment, the pooper valve adustment, and the sector shat edjustment. 3. Worm Shaft, Valve Thrust Bearing Preload Adjustment (With Vehicle Cngine OF remove input 3.41 Remove input coupling, end protector (1) and ‘coupling; clean lean worm linout) shaft (2581 by fulluwing worm (input) shaft Procedure 2.1 and its succosding warning, Femove and plug 3.2 Remove and pluy dhe ceturn line. SEE FIGURF 20, return fine, Tape page 1. lave serrations with one layer of tone. serrations Femove upper cover 3.4 Remove four upper cover brits {7A} and washers bolts and weshers (78), SEE FIGURE 28, 8718 inch sooker cere remove upper 4.4 Carefully remove upper sover (71 assembly from cover assembly ‘worm shaft [25B) whle maintaining the vabw casgernbly 116) posivan, SEE FIGURE 23. reassomble one 9.5 _Reassernble une holt (7A) vith a spacer of bolt spacers about thy width af the uoper cover (7) bolt flange and torqu bolt enugh to hole asernled components in positon SEE FIGURE 30. tunstake bearing —3.6Unstate the beeriny lockwasier {12} tang that is lockwesher staked inte slot in bearing lock rut (14), SEE FGURE 81. Romave tape irom serrations tomove bearing 37 Place a 3/4 or 15/16 inch 12 point sucket as lockwasher and nut required on worm shaft serretions end a hook type. spannar wroich ar self gripping Igroove joint) pers on bearing fock nut (11) and tum rat oof of warm shafi. Remove and sistrd beerng lockovasher (121, SEC FIGUNE 27assemble new hearing loskwasher, then aut torque hearing lock nut ‘NOTE remove belt and spacers assemble upger cover assemble and torque bolts complet the gear teessembly 18 3a 38 ao an 312 ang Assemble a new bearing lackwesher (121 ante worry shaft (258) with the intemal wesher vng in’ he worm shaft sor and the exteanal tangs foxing out. Reussombie bearing lock nur 11, laige chamfer side in, ontu threaded dnote at wort shaft unt eortaonenns are al solid fight {snug}. SEE FIGURE 33, Torque the bearing Jock nut (111 to 30-4, bs MIN m} to ensure components we sealed. Back the rut otf ard torque nut 10 15-20 ft Is, (20-27 Nm), SEE FIGLIE $4. Back nut oft apnraximarely 201° and bend one tang ot Deering Inclewnsher 112) firmiy inia a mating slot i lock it. SEE FIBURF 36. NOTE: It is recommended that seal (4) in the removed upper cever (7) ané backup washer {10} and o-ring (10A) on poppet adjusting serew (9) bo replacad por the disassembly and assembly procedures in this manual befare ‘upper cover is reassembled. Rernove the ane bul (PAI srl spares used ta contein companents dung aulusivent, Tepe worm sheltserretins, Grease and install a new seal ring (8} 11 upper cover [7] and essombla uppar cover and edjusting scthyy assembly onto the warm shaft (258), ‘neering the pamper adusting sos 19) inte vale 116) and adaptor (201 as required. SFE FIGURE 36 Assemble the four bolts (7A) and washers (7B) RR ‘nto upper cover (71. Carefully torcuo the bal ACW while chosking that the adaptor {20}, valve N assembly 118) end upper cover are aropely viloted and pusiianed with all eal rings in place, Tugue bolts to 26-35 ft ls. {94-47 NV mb if dey, ov 21-27 4 hs, (2837 Nm) i lubricated, SHE FIGURE 37, Cunplore the steering gonr rrascemly by fulowing aravedures 2.6 through 2.11 gute 37set arle stops 4.1 install flow 42 meter rotate sector 4a shaft CAUTION NOTE loosen jam mut 44 and adjusting screw sat adjusting 16 ‘screw and tighten jam nut adjust other 16 poppet Poppet Valve Adjustment (With Vehicle Fngine Dn} Before you adjust the ponpets, sat the ade stops according 1 the manufaciure’s sperifizarions. Install © pressure gage or e flow metorfprassure gage package ireo the supply ine fom ie pura Uo the gear. Make sire that the flow meter can be pressurized. Oring the fluid temperature to between 125% and 13°F (O1.F%C and 57.2%, using the method to warm the system up described in tie wuubleshaoring sectin, age 8, With the engine st idle, have someone turn the steuting wheel 1 full lok, laxle ayeinst axe slop) while you observe the rotation of the sector sho 46). SEF FIGURE 28, H the sector shaft Tulales counter-tlockwise as shown, acjust the poppet adjusting sorew identified i the agprouiale view shown in figure 38. If the sector shalt rotates lackwise, edist the ether poppet adjusting sore CAUTION: If system relief pressure is reached while the steering wheel is at full lock (axle against zxle stopl, release the steering wheel from this position. At no time should system ‘elie! pressure be maintained for longer than 8 seconds as damage to the pump may result, NOTE: You must maintain enough force on the Steering wheal to assure thal the steering gear control valve is completely closed when reading pressure gage. Once you hove derermined which poppet to aujust,Jousen the. papper adjusting serew jen nut 16 oF 491 and the nonpet adjusting sorew 19 or 481 und the pressure gage reads maximum system pressure with swering util at full Ik SFE FIGURE 30, Manual¥y ne power tol and cere screw in ‘the poppet adjusting serew {9 or 48 thet is being adjusted unt prossure gage shows a significant pressure drog (700-400 psif with the axle contacting aale ston fl Ie, Torque tne related acting sere jar nut (6) to 19-20 ft. las. (20-27 N ml or jam nut {49} 70 20-25 ft Ibs. (2434 N on}. V2 inch or THB inch socket required. To adjust the ather pogpet, repeat these insirucuns for full lark in the ovher direction, SEE FIGURE 49, ‘Ade Ts Poppet Serer Figure 38 Figure a1 9locate adjusting nut NOTE remove the drag link CAUTION NOTE center the sector shaft check for fash position adiusting serew check for lash eliminate lash fecheck for lash connect frag link a 4 §1 53 55 56 58 5g Cross-shaft or Sector-shaft Adjustment (With vohicle engire off) 1 the sector shaft adiusting screw jam aut 130) located on the aide covar (38), is na anczssblo, the steering geat must be remaved prior 1a adjusirent, NOTE: If there is not a timing mark on the end of sector shaft {48} a timing mark must fe scribed across the end of the sector shaft perpendicular to the worm shaft (25B) while the vehicle's steered wheels are in the straight ahead position and the dray link is in place. The timing mark will indicate the sector shaft “center of travel” position, Uf the sector sheft adjusting screw 145) is avoessible, remove the drag lnk from the citman orn. CAUTION: This adjustment must be performed with the sector shaft on its canter cf travel, NOTE: Because of pitman arm or internal stops of poppe! adjustment the “center of trevel” for this adjustment may not be the center of sector shaft cr handwheel rotation. To pastian the snetor shaft (48) on “cantor of tuavel” for this adjusiment wlale steering wheel {warm staft) until the ining mark aurose the end of the sector shall ie perendular ta the weer shaft (258), SEE RGURE 41, With the sectur shaft (46) ii the center positisn, tuasn the pitman arm and gently (ry to mave this army back and fort in the diretion of tava Fingersip fore is adequate to detgct lash of a loose sector shalt, There must be na. mavernent of the input (worm! shat or sestor shaft, It no lash is detected, do not adjust, SEE FIGURE 42 IC fas is datected, louse jain mu (97) with a 3H inch socket and move the aujusting screw 14) clockwise until the sector shett and reck piston (3a) are in contact. (Use no mare than 10 ft. Ibs. (14 Nr} of torquel, Than turn the atjusting serew counerciockavise one turn AA this point, there should be last et the pitman am, Tu ads, slowly tun the adjusting srrews (46) clockwise untl no las is fet ai the pitman erm Hold the adjustig sorew in place, and tighten the jam nut (37), Then lorgue nut to 40-45 it Is. (54-61 N ml, Fecheck the pitman etm for fash. Turn the steering wheel 1/4 tum sech side ot verter. No lash should be felt H lash exists, peat adjustments 5,348 Reconnect drag lik to pitrian arnTorque Chart Part Name Upper Cover Bolts Upper Cover Bulls Poppet Seat Locking Screw (Ball Nut! Ataptar Balt ‘Magar Balt Sie Covar Bolts Site Cover Bolts Trunmion Cover Serews Trunnion Caver Screws Poppet Adj. Nur Poppet Ag) Nut sq) Ponpet Adj. Nut Hig Aj. Nut {Sactor Shaft} Sector Shaft Nu Pitman Arm Bolt & Nut Assy Pirman Arm Holt & Nut Assy tem Number Torque TA 25-39 ft tbs. ( 34 47 Nm) 7A il Lutrivated ‘2-21 tt, Ibs, ( 28- 37 Nm) 82 G- 3D ft. Ibs, | 34-41 -N in} 36 aD 35 ft. Ibs. | 41-47 Nm) 204 70. 80 ft, Ibs. | $5108 N mp 2UA it Lubricated 47 87 f1, Ihs, | 64 77 N mb SBA 150-170 f. ths. 1203230 N mb 38A it Lubricated 108-128 ft. ths. (146-1/4 N ml GA, ‘1d 24 ft Ibs. ( 18 31 N ml ‘2A if Lubricated T1- 16 Th Ibs. ( 16 22 N mp B 1S 20 IL Ibs. ( 20- 27 Nm) 4g ‘20-26 I. Ibs. ( 27 34.N mj 4a 20 25 ft. lis. | 2 34 Nan} a 40- 45 ft. tbs. | 4 1 Nom} BAR 75-600 ft. Ibs. (644-6/8 N mul 380-420 ft tbs. (515-059 Nl LubricatenPlated 300-920 ft. Ibs. (407-434 N mi Universal joi holis—torque «0 vehicle manufactur speifvations. Al torques sweet in this monuel are for drytunpated parts uikss vtherwise specified Tools and Materials Required for Ser Service Manat Masking Tape ur Spacia Clip trease—*Mabil Tema 1 or 2 or equivelent Whes! Bearing Grease Aqusteblo Wrone! Packer Knile Torque Wrench—in ts. 1m) Torque wrench, bs. N ml Soft Punch Rubber Mallat Vise 1" or 25 mm Mivometer Emery Peper Specel Mvbor #GAT913 {See Sketch) Retaining Ring Piers Breaker Bar 7-08 x45 Gia 313.308 0 200. 275 inorsons Shown im MeReS G7 cop ing Ratchet Sockets: 12, 816, 11/18 inch Allen Sockets: 144, 3/8 ined 12-Point Sarkere: 34, 1 Pitman Arma Puller Seren Driver Slot Typs Screwdriver Sankes Chisel 334" to 2" Adjustable Hook Snanner Wrench Small Nosdle Nose Plies Bering Mariel Lequic Grads “1” Primer Sit Lock Lita Hyclaulie Seatant inch 1 184 Dn, a ca ham, with within O1OTAR: To be Fabricated By Customer "Mibil Temp is Fegiseod Tacemark of obi Gil CoHF64 Exploded Assembly View — Typical 62) 1A-8 EOD 2Aaa a i “0 jeordAl — mal, Aiquiassy papojdxg 94H neDisassembly Preparation * THOROUGHLY CLEAN OFT ALL OUTSIDC DIRT, ESPECIALLY FROM AROUND FITTINGS AND HOSE CONNECTIONS, BEFORE YOU NEMOVE THE GEAR. © Drain the steering gear assembly, © Hemove input and output sheft connections per 1.1 and 2.1, Page 12 and 16, © Memuve the supply and retum ines fram the gon, and immediatly pug all por hules and fui lines. WARNING: THIS STEERING GEAR WEIGHS APPROXIMATELY 74 POUNDS 34 KG DRY. EXERCISE CAUTION WHEN YOU REMOVE, LIFT, OR CARRY IT. 0D NOT POUND THE UNIVERSAL JOINT OR INPUT SHAFT COUPLING ON OR OFF THE INPUT SHAFT. INTERNAL DAMAGE TO THE STEERING GEAR CAN RESULT. Remove the steering geer trom the vehicle and tke iit # slean surlaue la piece ct wrapping paner makes an excellant disposable top, © Clean and dry the pear before yuu stert to disessembe it © As you disassanbie the gear, eean all pars in clan, netrnlein-hased sohent, ‘and blow them dry only. WARNING: SINCE THEY ARE FLAMMABLE, BE EXTREMELY CAREFUL WHEN USING ANY SOLVENT. EVEN A SMALL EXPLOSION OR FIRE COULD CAUSE INJURY OR DEATH, WARNING: WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA OR OTHER MAXIMUM AIR PRESSURE REQUIREMENTS. CAUTION: Naver steam clean at Figh pressure wash hydraulic steering components. Uo not force or ahuse closely fitted parts, © Keep each pelt seperate to evoid nicks and burs, Discard all seals, O-ings, end gaskets removed from the gear. Replace ahem Disassembly position goar 1, Postion the stasiing goor firmly in a vio, in vise clamping aginst the housing 147) maurving flange cr boss, with the wm shaft (958) in a Friant! ditection ard components accesible fr cisessumbly, SIE FIGURE 92 CAUTION CAUTION: Do not clamp agsinst body of the housing as this cculd damage housing and cause disassembly, assombly difficulties, If housing maunting boss or flange is nat accessible for clamping in vise, fabricata and attach a mounting plate to the housing mounting bosses for this purpose rain year and 2. Prepare for fluid drainage and unplug hydraulic position ports. Lsing the apnrapriare 3/4 or 13/76 inch 12 sector shaft point socket an the viarm shait serrations, rotate ‘worm shalt (258) through gear travel a few times lo puryo hydraulic full from guar. Than 2 gure 43 TIMING MARI.NOTE remove protector seal lean sectar shaft remove trunnion cover screws remove trunnion cover and seal package loosen sector shaft agusting ssorew jam nut 5. 6 fotete the wornshaft unt the tining mack an the end of the sector shatt (1) & vertin! (80°) to the worm stn, This will position the gear fr Sector shaft remaval, SEE HIGURE 44. NOTE: if the steering gear does nat have a sector shaft timing mark, position sector shatt for removal by rotating worm sheft from ond of travel one half of the total worm shaft Totetions counted when rotating worm shaft ‘rom ong and of travel to the ether. Remove protector seal (3) tram trunnion cover IW2L SEE FIGUAE 45, Romave any pi! wr cotrsian from the exposed aren of sector shalt with eniery cla. SEE TIBURE af Remave the four (vunriut cover sires (2A A 1/4 inch Alen socket required, SEC FIGURE 4/ Remove she trunnion caver (62). Remove end discard the seal ring 151), Uie wu piece sector shall s2al (4a) and the Teflon tackup washer 142 Irom thy trunnion eaver. SEE FIGURE 48. Loasen suutor shaft edjasting serew nut 187), SEL HBURE 49, A514 inch sucker is require. Figure 48remove side 8 cover holts NOTE remove side 8 cover and sector shaft assembly NOTE remave sector 10. shaft from side cover remove side WW seal reteiner 2 Prepare for fli (0 drain and remove the six special bolts (J8A| trom side cover 38). A 18/16, inch socket required. SEE FIGURE SU, Tap lightly wth soft fare hammer cr the and of sector shaf (46] tn tisengage sen! and let drain, NOTE: These holts are special because they are equipped with either a ring or washer design on the underside of the head, SEE FIGURE 51. If you replace one or more bolts, ‘you must uso bolts of either design and of the SAME SPECIAL TYPE AND LENGTH AS THOSE YOU REMOVED. Do not use a substitute, You can get these bolts through your DEM parts distributor, Pemave side cover (38) and shaft assemhly (Al ‘3 @ unit {rom gear assembly. SEC FIGUNL 62. Remove and decart sual ing (38 NOTE: If sector shaft hangs up on housing face during removal rotate worm shaft until sector shaft is positioned for removal. Remewe jem nur (97) and stew sector sha adusting screw G45] out of side cover (36) end lift sector left (46) cut of side cover, SEE FIGURE 9. flemove the side cover retaining ring (438). SEE HGURE A Figure 81 Fiyuu 64remove seal 12, package and vent plug ‘remove retainer 13, and adjusting screw remove seal 14, and clean worm shaft NOTE: loosen upper 1b cover bolts and adjusting nut temave adaptor 16 bolts Remove the two plece seal Ma, the Teflon tackup washer J} and steel backup woshar (1) frum side cover {38}, Discord the nwo piece seal ad Teflor washer. SFF FIGURE 6 Remove and discard vant plug (900 Only if replacement of reteine 44) and or arfusting sore 14) is required, (ee inspeution rocedure #9, page 36} sloca the secta sel (46) firmly tv sr jawed vise and uneteke ‘etainer using a suitable chisel. Tum retainer out af seotar shaft pocket and remove adjusting sore. Discard retainer. SEL FIGURE hf Rernave protector seal 11) trom worm shaft (258). Clear exposed eva af the worn shaft with a fine grade af emery paper. SCL FIGURE 57 NOTE: Seribing or marking a line across the housing (47) adaptor (20) velve body (18) and upaer cover (7) before cisassembly will facilitate correct alignment of these components when reassembled, Loosen the four upyer cover balis (7A) ancl poppet adjusting screw nut 16) fur ater sermaval AAG inch and 12 inch socket reyuited, SCE FIGURE 8 Remove four adaptor bulls [20A) end washers (208), A 3/4 ier socket required, SEE HIBURE 48 Figure 56 25rotate worn v. shaft to loosen acaptor remove voi tN shaft subassembly unstake and n" remove locking washer and screw position rack mn piston and disengege from ball nut WARNING 6 Rotete worn stall {2801 until a aveey trom housing (471, eat and let dran. SEE FIGURE BO. 4 inch 119. mm} Rusmoe warm shafy 1268}, upper caver (7) catlaplur (201 rack pistan (351 suhassemhly as a unit from huusing {27} and place on a clata cayered work surlace, with Ye rack (wel up SEE FIGURE 61. Remove and disard eal sing (211 aud seal ring (194. Unsiake lacking washer (384) from lacking serew (61 in the reek piston (351 with suitable chisel SCE FIGURE 82. Nemeve locking sereay and lucking washer from rack piston, Discard washer. A3IB inch Alen socket vequired. SEE FIGURE 63, Positian the rack piston (5) with rack teeth down and disengage rock slowly from subassembly until approximately 1 inch (28.4 mm| of the assembled ball nut 6A) is exposed. Wine the exposed boll nul dry and glace retaining cia ov tae over bell return quide (267) to retain the quide ond balls in ball nut. Complete the removal oi rack gist ‘yom subassembly, SEE FIGURE 64. WARNING: IF BALL NUT, BALL RETURN GUIDES AND BALLS BECOME DISASSEMBLED, EXTREME CARE MUST BE EXERCISED TO REASSEMBLE THESE PARTS. 17 1S IMPERATIVE THAT THE BALL NUT ASSEMBLY PROCEDURES IN THIS MANUAL BE FOLLOWED, INCORRECT ASSEMBLY CAN RESULT IN A BALL ESCAPING ANO CAUSING A LOCK UP OF THE STEERING GEAR. THIS COULD RESULT IN AN ACCIDENT. Figure 0 Figure 82 figure 84cul and remove 21 rack piston 0a! ring end ring tunstake poppet 2. loclewasher Yemove poppet = 24 seat, lnckwasher and poppet ceut and remove 4 worm shalt seal remove retainers 7h, and washers Position the rack piston 1861 in & ise clanging agairst unmachined surfaees. Cut and remove seal fing (B4A\ and wring (948) fram rack piston, SEE HURE 68. IF the rack piston has east mata rng (84) remove it onl ili ta be rophoed. issardl remnved rings Gniy if aeppat ea is to be replace, unsake lockwasher (32A) fram poppet seat 192! in tack piston 195) with suitshls chisel. SEE FICURE 68. Then remove. pognet seat 132) leckwasher (328) and poppat 2) fram rack piston 136), A 9/16 inch socket required. SCE FIGURE 67 ‘While holding therm stationary with piers to srevent sipping, cut, remnve, ard discard the seal cup (281 an seal (771 fram ball nut env of wor shoft 1258}. SEE FIGUNC 80 flemove rataning ring 141) using neeile nose plies, then cemeva rersining washer 130) beonee washer 129) and sive! washer (261 from hall nut end of warm shaft (288), SEE FIGURES 89 & 71 aremove ball nut 26 assembly disassemale ball 27 ‘fut assembly if necessary CAUTION remove ball 28 return guides and balls OTE 2B UF special mandrel GATONS is wveiluble see tools on page 211, place merel in hale at tall nut end nf avorm shaft [2uB} ard sorow tho bal rut assermbly (254) onin rnanirel, SEE HGURES 71. & 72, Carofully remove mandrel and ball ut agvombly and set aside with ball nut up. IT the suecial ball nut mandrat (GA1878} is nat available, (unm (he all rut assembly (2481 aft the worm shot [26B! wer the doth work surlace 10 ccetch the bas (25D and 261 thet weil fall cit Se FIGURE 73, CAUTION: {fF one or more balls are lost oF damaged, the complete set of 28 balls must be replaced with 2 service boll kit, ‘Thon remove the tape ar dip, the ball return twuides (25H and the balanse of balls (260, 2bE) From the ball nut 1250). SEF FIBURF 14. NOTE: If the set of 28 balls removed from ball nut are to be reessembled set them aside for cleaning, mezsuring, and segregating by site into two groups.remove upper 2, cover, bolts, ‘and washers remove poppet a0. adjusting screw and nut NOTE remove upper av over retaining ring and seal package remove adaptor 29. from worm sheft Retrove the four lvosened upper cover batts (7A, washers (78) ard thy upper caver (7} assembly from the worm stafi (260) subassembiy, SEE FIGURE 7. Discard seal rim 18) Remove the loosened nut 16 rum the puppet adistng strew (9), Than turn the adjusting seven vat of the upper ever (7), Hemme and discerd back waster (10) and O-ring (GA) from adjusting serew, SEE MIBURE 78 NOTE: The adjusting screw (9) and nut (6) do not have to be removed from upger cover if only the backup washer (10) ané o-ring (10A} are to be repiaced. Remove retaining ring (2) from upper caver {71 vvith the ayarugriate rekaning sing ples, SEE HHGURE 77. Reine backup washer (31 and sesh VAL SEE FICURE 78, Aemove atantor (20) trom worm shut (250), SEL FIGURE 78. Remnave and discerd seal ring (8) and two see ngs 119)remove retaining 3, ring, seal end backup washer unstake locking 34, washer from nut remove bearing 3h, lock nut CAUTION remove washer 36, and thrust bearing package 30 Remnue retaning ring {24} fam adaprar 120), SEF FIGURE fl Remove ant ciseard seal 123} and backup washer (221 SEC TIGUNE al. Unstake the teng on bearing lookwasher {12) thet is sinked in-n slat of hoarng Isnannes) look nut (11 un the worry shaft, valve subassembly. SEE FIGURE 89 Use a breaker bar and he appranrints 3% or 13106 inch 12 puint suckut on tho surrations uF damp worm shall carefully in 8 so awe vie to hold warm shaft (258) from rotating. Turn otf ‘the beating lock aut (11) from the warm shatt ‘itt @ hook type spanner wrench or self arpping {grt0ve jont plors. SEE HGUNE 83 CAUTION: When the hearing locknut (11) is removed the valve assembly components are ro longer retained in the valve body. Care rust bo usod to koop the velvo assombly components assemmbied. Remove and discard bearing lock washer 121 and remave washer [13], thrust washer (14), thst tesring (151 spacer washer (16) and thrust washer (171. SEL FIGUNL 84 Figure 6remove valve 31 assembly CAUTION remove second 38 thrust bearing packege remove poppet a adjusting screw and nut from housing remove and all dscard backup washer and oving Carefully remove valve assembly 118) intact fram ‘warm shaft (268) end set aside for inapeclion and assombly procedures. Skt HUUAE 89, CAUTION: Tho valro assombly (18) is the conrrol center of the hydraulic system, The major parts, which are the body and spool, are ‘machined to very close tolerances and with precision machined edges. The valve savol and valve body ara soloctivoly fitted at the factory ‘and therefore these two parts are not separately replaceable, If either is damaged or excessively worn, the whole valve assembly should be replaced - good performance of power stesring is not assured if ““mis-matched” valve spool and valve body are used. Cere stould be exercised in the handling of these parts to prevent damaye. Sealing edges ot the valve body bore and the valve spool should not be broken, Thie wil rosult in excessive leakage and reduce hydraulic power. Should valve spool (188) or other valve components become disassembled, follow the assemly procedures with care, Remave the second thin thust washer (17), spacer wester {16} thiust Ueering (15) and the Thiek trust wesher |14} from worn shall (258). SFE FIGURE 86, Loosen nit (44) and remove nut ane paps dusting sore (48h froc housing 14/1, SEE FIGUAE a7, Remove end discard backuy wrslier (10A) and o-ing (101 irom adjusting serew (4B1. Aenrave rut 491 roplacoment is roquirad, SEE FICURE 88, 31press out 41. Prass- out besring (44 and retaining ring 160) housing fram housing (471 only if the bearing #8 10 be bearing replaced. Place suitable bearing mandrel against assombly the side caver end of bearing and prnss bearing ut of the trunnian end uf bearing bure. Remove Fotairing ring from beating and discard besrin, SEE FIGURE 89. CAUTION CAUTION: 1f the bearing is eacked while you press il ovt, it will bursish the aore, causing it to become oversized. You will then have to replace the gear housing. press out 42, Pross hearing (5) nur af upper enver (7) with the upper cover bearing mencrel ogcnst seal erd af benring and bearing only if it is to be replaced. SEC FIGURE 8. ra 90 This completes tha disassembly of HEB stesting gealInspection * Check to make sure that all weeny surfaces and seal cavities ave free trom nicks and corrosion. If any parl is nicked or corroded where saaing occurs, you ‘must replace the part t sure proper svaling, © Wash all perte in clean petroleum-based solvent. Blow tham dry with air only, WARNING WARNING: SINCE THEY ARE FLAMMABLE, BE EXTREMELY CAREFUL WHEN USING ANY SOLVENT. EVEN A SMALL EXPLOSION OR FIRE COULD CAUSE INJURY OR DEATH. WARNING WARNING: WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA OR OTHER MAXIMURI AIR PRESSURE REQUIREMENTS. inspect rack 1. Inspaet rack piston (85) veeth for cracks ard fiston teeth ‘wear, If you can detect a step by running your fingernail horzontally aorase be well surface, Yyou musi repane the rack piston and sector shaft (48), Carefully ingneer the rece piston bores an outer ground surfares for damage and stone uff ay burs, SLE FIGURES 91 and 82 inspect worm 7. Inspect the worm shall 12681 and the hell nut shaft & ball 1P5C) bab treck gracwes for brinullng ur spain. nut SEE FIGURE 93, It ether consivion exists, in wither compnnents, you must replece worn shaft ‘and boll nut ssaembly (251. Visually inspect the worn! shaft upper seal aree near the serrated end or nieks, and run your fingnmal edge acrcss the sealing surface 10 dorest stops, SEE FIGURE £4. Visually insgeet the value spol (1B) contact area of the worm shaft for dscnlaratinn fram excess heat. I either uf these conditions exist you must replace the worm shaft, wall nur, valve, rack piston, adepror, upper cover assomty. NOTE NOTE: Hf » bal (250) or (256) in the ball nut assembly (26A) is lost during disassembly or assembly procedures, all 28 balls must be replaced as a sel utilzing a service ball kit, Damaged bats would require you replace worm shaft and ball nut assembly. inspect value 3. Inspect valve spool T1881 and valu body [i841 assembly bore for broken sealing edges. SEE FIGURE 95, Figure $1 Figure 92 Figure 94CAUTION inspect thrust 4 washers and bearing inspect housing 4 cylinder bore NOTE insect housing. faces 4 CAUTION: The vaive essembly (18) is the control center of the hydraulic system. The major parts, which ere the body and spool, are machined to very close tolerance and with precision machinod edges. The valve spoo| end valve body are selectively fitted at the factory and therefore these two parts are not separately replaceable. If either is éameged or excessively worn, the whole valve assembly should be replaced - good performance af power steering is not essured if “is-matched” valve spool and valve body are uso, Care should be exercised in the handling of these parts to prevent camage, Sealing arlgas of the valve body bore and the valve spool should not be broken, This will resut in ‘excessive leakage and reduce hycraulic power Should valve spool (188) or other valve components become disassembled, folow the assembly proceduras with care. Inspect the thrust bearing [16) cols for any daterioretion. Inspect the thrust washers (12) and 114) for bnneting, saling, os eracks, SEE FIBUR 95, Reploe the part it you detect these conditions, Inspect the housing (471 cylinder nove, SEE FIGURE 97. You will probably notice narra scoring marks running lengthwise through the bare. Since this ssaring i noral, you shoule: not ampere it te the scoring considered detimentel in the cylinder bores of an internal somuston engine, Replace the housing aniy if you've tested it for internal leakage las descrbed in the troubleshooting section! on page 7) and you've determined that tho storing, and nat damoged seal, is responsible fo the excessive intamnal fenkage, greater then 1.8 GPM 16.7 liters. NOTE: In running the internal leakaye test alter reassembly of the unit, make sure that internal leakage exceeding 1.5 GPM (6.7 ‘itersjmin.} can only be attrbuted to the housing ard not to the improper assembly of the new seals in the worm shaft, rack piston, and valve assembly, befsre you replace the housing. Inspect tre housing (47) fares tor nicks thet Would prevent proper sealing. Replace the gaar housing if these nicks are presert and cannot be easily removed with a finetocthed flatfile witout ctanging the dimensional cheractarsies. SEE FIGURE 8. Figure 9Binspect housing 7 and side covor bearings inspect sector a shalt assembly NOTE inspact 4 adjusting screw and retainer Inspect the housing bearing (40) and the side cuver bearing for brineling or spaling, SEE FIGURES 98 & 100. If either condition exists, repleca the demayod hauring boaring (AU), For the housing beaing, falow disassembly step 41 and assembly step 1, payes 92 and 38. I the side coves keering is demged, replace side cover assembly (28) ‘nspeot the sector shift 146) bearing art sealing frees and sector teeth contact surates for brineling or spaling. SEE FIGURE 101. Aun your fingornll edge astass these areas to detect stops Insaeet also for trarks. Remove any masking tape trom the shalt serrations and inspect for mised or otherwise damaged serrations, IF any of these conditions oxisi, replace the sector ska NOTE: A servica shaft assembly will have the adjusting screw (45) and retainer (44) assembled into it. The screw (46) and retainer (44) can be serviced separately if required Inspect tha sector shaft assembly for derraged adjusting screw (86) threeds. The staked retainer 144} must be locéed in nlsre, and have no cracks. The adjusting scrow must rotato by hard with mo perceptible end play lash, Replace adjusting seraw, damaged. Replace the retine damaged, or if the adjusting sorews requires replacement or adjustment, Refer to the essembly zat isassorbly procedures. This completes inspection of the IITA steering goar. Figure 107 %Assembly Preparation © Wash ell parte in clean peteoleum-dased solvent. Blow them dey anly WARNING WARNING WARNING: SINCE THEY ARE FLAMIMABLE, BE EXTREMELY CAREFUL WHEN USING ANY SOLVENT. EVEN A SMALL EXPLOSION OF FIRE COULD CAUSE INJURY OR DEATH. WARNING: WEAR EYE PROTECTION AND BE ‘SURE TO COMPLY WITH OSHA OR OTHER MAXIMUM AIR PRESSURE REGUIREMENTS. © Replace all seals end seal rings with new ures eact time you disassemble ‘he goar. © Rosy Guer doze provide individual seals, seal rings, as well as coraplet® anc! partial sual kis, SEE FIGURF 102, Thuse parts should be aveileble through most OEM farts distributors. (Comact your local dealer for availebity.| Assembly install housing bearing end retaining ring install bearing into upper cover clamp valve body of essembled valve body in viso 8 Ui you are installing 2 new housing bearing HU) first install the retaining ving 1501 into the. grocun an the boaring’s uuside diameter. Place the housing (471, side cover face dawn on ¢ woadan hick lv piotect the foce, Using a suitable beating mandrel, caratlly pross the lang end of the bwering imo the hausing fran: the trunnion cover se until the retaining ring cuntacts the hows, SEE AIBURE 102. During this procedure be sure ‘he housing 1s square with press base ancl the baring is nut vucked, Lubriceta hearing and set housing aside I) you ere instaling a nawr needle bearing (5 into ine upper cover (7), a suitable pressing mandrel must be fibricated which wll pit on the inner diameter af thy nod bearing and have cloaranve in tie bearing bore. Place the mandiel against the lettered end of hearing and press leering into upper cower bearing bore frum the valve fece sce until the bearing is positioned 1.13 inch [28 mm} from unpar cover vale face. Afer the bearing assembly fs pressed in upper cover the bearing rolls must orb and ovate teal in bearing shel, Lubrisoe beorng, SEE FIGURE 10, Ascemble & hydraulic fting securely in volve bady (TEA\ tiyraulc port. Carrp velve body assembled ut disassembled securely in a vise, clamping, against the hydraule fisting or part busses. Positon valve body in the Vise sy Ural worm shaft, edaptor ond upper cover can be assembled, SEE FIGURE 108. Figure 108 Figure 104 Figure 105,CAUTION CAUTION CAUTION NOTE ascombly of 4, valve spool assemble 5 plungers and spring sets NOTE CAUTION: Use only the correct size standard 314-16 |¥8) ar 9116-18 (6) JIC straight threaded port, oving hydraulic fitting in the valve ports. The use of 2 wrong fitting such ‘as a pipe fitting will damage the valve port and require replacement of the complete valve assembly. CAUTION: Clamp valve body only as directed and uso care not to clamp against mechined valve faces or sides of valve body. This could damage sealing surfaces or distort valve bore. When clariping against valve port basses do not tighten vise with extreme force as this could distort valve ports. CAUTION: The valve assembly is unique to the particular HFBA steering gear flow rate appication. Use only the specified valve assembly replacement ta ensure proper operation. NOTE: If valve assembly components are not disassembled go to essernbly procedure #7, If valve assembly 118) has become disassembled, refer to the snlsrged exploded view ov yages 218 & 218, Assemble valve spool 188) inta valve body (IBA). Tha end af the valve spool wth iertfcetion grooves in the bare or in the undercut or relief on the curside diameter must be lowerd the adaptor side or fase of valve body ‘ter assembiy. The adaptor side ur face of the valve body has two (blind! cylinder food lines thay dh not extend! through 70 the opposite lace, On some vale bodies the cest identification # boss is pointed on the cnc tword the adapior sile or fava, SEE FISURE 106. Assemble # plunger (TBC, @ spring (18D), and another plunger 118 in that order in the sit through holes in the valve body (184) 9s shown in the enle god auxiliary view on fold ont pages See HIGURE 117 NOTE: Some valve assemblies (18) may have one inactive (long) plunger instead of the set of two reaction plungors (18C) and o spring (180) in four of the plunger holes in the valve body (718A), Assemble these inactive (ong) piungers evenly as possible among the reaction plungers (18C) sets in the circle of plunger holes if their original positioning was not noted uring disassemly Figure 106 Figure 108NOTE assembly of 4 check valve plungers and springs CAUTION assemble first 1 thrust bearing package on worm shaft assemble worm 4 subassembly into valve assembly assemble thrust bearing packoge assemble in bearing lockwasher and nut CAUTION torque bearing n lock nut 3B NOTE: Two ail transfer holes in the circle of plunger holes as designated in the exlarged view are too small fo accept plungers. I the chack valve jlungers have becone ulsasseiiled. Assemble a ball MBH) and conical spring 11861, small end ist, inta the wa check valve plungers (1BE| Assemble nne check plunger acsemtly, a spring !180) and then the other check valve assembly inta a plunuer hole as shown inte exploded view. Sorina end of check valve plungers must ie facing loward the spving (1BOI. SEE FIGURE 108, CAUTION: You must ha full complement of reaction plunger sets, inactive plungers and a check valve plunger in the circle of alunger holes for the valve assombly to function perly, Only two al transfer holes in the circle of plunger holes should be empty. Assemble @ thick thiust wesher (14), specer washer |16), thrust bearing (151 over spacer washer, and a thin thrust washer (17) an the inwut serrated! end af worm sha‘t |25B) snd against worn sift shoulder. SEE FIGURE 103, Assemble the input Iserrated} end o! the woin shaft (26B) with baaring package into the adaptor ‘end of the valve spoal (188) bore as described in travers €4, until shaft and bearing assembly stups against the spoul. SEE FIGUAC 110, Assemble the other thin theust washer (17, spacer washer (18), thrust bearing 116) aver spaver washer ane thick thrust washer (I4) anto the input (serrated) end of worn shaft I25BI and ayainst the vahe spool (188), SEE FIGURE 111 Asgerchle weahar (13) than a naw bearing look- washer (12) onto warm shaft 1250). The internal washz langs must enter sot in worn: shalt and the oxterel tange of bearing lockwashor must fece our, SEE FIGURE 112. Assemble bearing look nut 1), large eharfer side in, onto thread darter of werm shaft until cormponents are at sold height and stg eoainst valve spool (183) CAUTION: Be sure that spacer washers (16) are encircled by thrust bearings (15). Torque the bearing nut 111) t0 90 ft bs. 141 rm) {0 eat tho components, Beck the nut off end then torque 10 15-20 ft Ibs. 20-27 Nm), SEE FIGURE 112. lack the rat off approximately 20 agrees and bend one tang sf lack wesher 112] into a matching nut slot. SEE FIGURE 114. & Figure 113 Figure 114check worm 1 shaft rotation NOTE assemble 18 washer seal and retainer into adaptor asserbe seal 14 rings assemble 16 adaptor on ‘worm assembly NOTE hook wpe spanner wrench, @ 3'4 or 13/16 inch 1 point socket and a ft. Th. (N in} twique wrench required Check for Fee rotation of worm shaft (258) volve essambly 118) end for perceptible end play ‘SEF FIGURE 118, NOTE: The worm shaft in the above essembly should rotate et 3 to 5 inch Ibs. (.24 ta 57 Nm). No end play should be evident. Assemble neve back up washer (221 and then new seal 123) intu adautur (201 sv that seel ips are ‘acing oul of seal cavity, SEE FIGURE 116. Assemble reteining ring (2A). SEE FIGURE 117 Coat eer neve seal ing ineally with clean gresst for retentian an assombie new seal ring (21), au mew seal ring (194), new soal ring 1) avd seu mew seal rings {GAL in the aoproprate tocossas provided tr uot sides af adspror 20h SEE FIGUAE 118. Assemble the adaptor (20) onin the rack pistun ond of worm shaft |?6A} assembly with the side with four tineaded Holes against The fore nt the vale assembly and the poppet adjusting scrow holes and ofinder fezd hls in auepir end vale body aligned (bl. SEE HIGURE 119 NOTE: If @ line was scribed across these components before disassembly you can now utilize the fine to align these components, Figure 115 Figure 110 Eyassemble 16 upper cover ‘seal, washer, retaining ving and seal ring assemble poppet 17. adjusting serew assomble poppet 18. aaijusting screw nut ‘tape worm 13, shalt serrations 40) On a clean work suilace, assemble new seal (4) into upper cover 7) with the saa) Ip faxing tho uppes cover bearing. Grease and assemble banicup ‘washer (3), SEF AIGUIRF 170. Insial retaining cing (2) securely into the upper cover retaining ring grout. Use anpropriate retaining ring alirs or & small serow driver. SEE FIGURE 121. Ayply clean reese fburally tw new seel ring (8) eid asserble it intu the revess urovided in the upper cover ‘muuning fave, Assemole new ack up ting (1U) on adjusting screw (91, Coat new ering {108} liberally with clan grease ur ul a essemble & carefully aver ‘the non-thieaded end of adjusting screw. SEE FIGURE 122. If tha adjusting stew hes been removed from te uaper cover, tread the sew ‘through the upper caver 171 fom the adaptor face side until 56 inch (14 mm} of thread is exposed uuyond the boss. SEE FIGURE 173, Assembla poppet adjusting serow nut (Bp, Hit was removed, una the adjusting sorew (8 finger tight, Final ajustment and torque must be made lore, Tepe the worn shoft 126B1 serrations and lightly coat the remaining portion of the worm shat with ol, SEF FIGURE 124, Figur 122 WEES Figure 123 Figuro 124install upper 0. cover assemble 2 upper caver bolts and washers acsomble ball 22, rut assembly fon worm shaft install ball nut 4, on worm shaft WARNING NOTE Install upper enver 17) sembly carefuly over vwerr shaft (258) serrtions eligning the poppet adjusting swrew (9) with the adjusing screw hole in tha vale assembly {16} and adspror ascomly 20}. Insert the pugpet aljustiny screw thraugh i's hole in the valve assembly and engage the adjusting serewv hole in the adaptor unl the adaptor and unper cover are piloted and positioned egainst the valve assembly mating faves, SCE FIGURE 128 Assemble four upwer cover bolts 17A) and washers VE). Carefully tighion the bolis wile checking that the edeptor (201 valve assembly (161 and unner emer (7) fares are properly nlated and pstinned with ell seal rngs in ploce, Torque holts ta 25-96 f. ns 13447 N mbit ory, o¢ 24-21 ft ths. [28-97 Non if lubriated, S18 inch sockel regurei. SOE FIGURE 128, Remeve worm ahott as assembled from vise and lace it on a clean elath covered work surface ta retain loose bls Hold the piloted end af mandrot ang bell rut assembly (25AI against the button fend ct the worm shalt 1258), Rotate worm stafl to engoge ball nut assembly in the worm ball fronve and position tall nut hattwey along the ‘worm shaft bell groave length SEE FIGURE 127. It bal nut 12561 is completely disassemfled install it onto shati (2581 so that the end with a heye themfer goes on lest, SEE IGURE 126, WARNING: INCORRECT BALL NUT ASSEMBLY CAN RESULT IM A BALL ESCAPING AND CAUSING A LOCK UP OF THE STEERING GEAR. THIS COULD CAUSE AN ACCIDENT. EXTREME CARE MUST BE EXERCISED TO ASSEMBLE THE BALL NUT, BALLS AND BALL RETURN GUIDES CORRECTLY NOTE: If the original set of balls are boing reassembled, they must be segregated by micrometer measurement into a group of 14 large balls (25D) and 2 group of 14 smaller the spacer balls in a service bal kit. The set of original large (working) balls will measure 2006 inch (.01270 mm) larger than the spacer bells. SEE FIGURE 129. Figure 128 Figure 128 4)assemble 22 balls into ball nut WARNING install ball return guide halves and balls CAUTION WARNING retain ball return tide with tape or clip 4 26, 26. 0. To assamble the sut of balls align ball nut (250) hell acoess oles over the worn sheft bel irnaves. Insert 22 halls (ot the 26 total) ahorately ane. nrge ball (2401 then one small (svacer) bal (28E) ima the seme bal eooess hob. SEE FIGURE 130. Uso the eraser and of a pencl tw work each ball down the same ball yrnave path on one sda ofthe warm shaft and around and ip toward the other ball wevess hule. SEC FIGURE 131, When the 22nd bell is inserted, Uie first ball will be visible at the second hall eccoss hole and on the oppaste side of the wom shalt. WARNING: BE SURE EACH BALL INSFRTED. STARTS DOWN THE BALL GRODVE ON THE SAME SIDE OF THE WORM SHAFT. OO NOT ‘ALLOW THE WORM SHAFT OR BALL NUT TO ROTATE DURING BALL ASSEMBLY PROCEDURES UNTIL THE BALL RETURN GUIDES ARE RETAINED IN THE BALL NUT. SUCH ROTATION COULD MOVE A BALL OR BALLS INTO THE DEAD TRACK BEYOND THE BALL RETURN GUIDE PASSAGE OR LOOP RESULTING IN BALL LOSS OR STEERING GEAR LOCK-UP. Coat tho ball rotur guides 126F) fray with qlwase and insert he remaining B bells alernately large and small (black inta & guide hal. SEE FIGURE 132. Join the gude halves tagether end firmly seat this subassernoly inte. the ball acess holes in the boll mut 125C). SEC FIGURE 19 CAUTION: The giesse must hold the balls in the return guides until the guidas are sested in vail nut. WARNING: DO NOT SEAT THE BALL RETURN GUIDES WITH A HAMMER. DAMAGE TO THE GUIDES GAN RESULT IN SUBSEQUENT LOCK. UP OR LOSS OF STEERING. Agoly tape or cly to ball nut assembly tn retain the ball return guides in place, SEE FIGURE 134 ce Figure 134check ball nut 2, operation assemble seal 28, components on worm shaft CAUTION assemble a, retaining ring WARNING prime coat rack =), piston threaded Holes and mating paris install rack a piston, Ovi ‘and seal ring CAUTION Carefully rotete the bell nut |26A| assembly for is full travel, while checking tor binding and assuring ‘that all 28 balls are in the correct closed recirculating paih or loop. SEF FIGURE 138, Assemble steel washer 126) on the lower end of wim shatt (258), Assemble new snal 127) with tha shorp edged ace against the stax! washer, ‘the new szai cup 128) with (he tunped site: nver the chamfored fate of the seal, bronze backup waster (291 and rhe retaining washer (3Q1 with ils counter bare faeing out. SEE FICURE 138 CAUTION: Use care that the above seal Components ara assembled in correct sequence and that the soal, seal cup and retaining washer are facing in the direction stated to insure proper sealing Compress the somponents lust asseribled agrinst the shoulder of tho warm shatt and essunisle retaining ving (21), Be sure the retaining ring is firmly seated jn its grenue in the wvorm shaft and in the retaining waster {90} caunier bore, SEE FIGURE 13t. WARNING: IF THE RETAINING RING IS NOT PROPERLY SEATED THE SEAL PACKAGE MAY BE DISLODGED DURING OPERATION CAUSING LOSS OF POWER STEERING IN ONE DIRECTION. The threaded hole an tap of she rack piston 136) and if the poppet scat (321 is removed, the chresded hole in lege end face of the rack piston ‘must be cleened wilh clean clear solvent and awn dry with clean ai. Aagly “Logic” Grade “", nrimer tn these twa threeded holes inthe rack piston, to the “cleaned” lacking screw (36) (heads anu 10 the mew popper sent (321 threacs. Allow ten rninulas fur threads to dry. SEE FIBURE 138, Install new rock piston hack up Oring (3481 snd then te new Teflon seal ring (344) ori} applicable, us. Uie cast meval pistan ring (94) nto rack pstun (96). SEE FIGURE 130, Do not aver expand these rinys as you instal them, CAUTION: Tho O-ring (348) and Tefion ring I34A) are not interchangeable with tre cast metal ing (34), 43place rack piston vise, apply “Stud Lock” assemble poppet, lockwasher and poppet seet bend lockwesher to head of seat WARNING begin to assemble worm shaft ard ball nut into rack piston 4 2 38 4 35, Clamp reek pisinn (6) firmly in a soft jawed vise with teeth facing up and access to worm sla tore, quopet hale end ball nut lacking screw hole, 1 the puppet 891 ie being replaced, apply "Stud Lock" W Uie new poppel seat 192) threeds and the rack piston popaet hole thieads, SEE AGURE 140, Assemble new paper (3a) and mew luskwester (GA) into rack piston (354 yoapat hla, Sera new soppet seat (32) ito the papoel hole with ‘he luckwaster oorreetWy positioned in the slot provided, SEE FIGURE 147. Torque pappet seat to 25-30 I Ibs. [34-41 Nn. end up the radiused side of lockwasher [22Al firmly against the adjacert side uf the poppet seat had, SEE TIGURE 142. Figure 142 WARNING: IF POPPET ASSEMBLY PROCEDURES ARE NOT ADHERED TO, THE POPPET SEAT COULD BACK OUT CAUSING DAMAGE THAT COULD RESULT IN LOSS OF POWER ASSIST. Analy lean grease ta ses cup 1281 and enter the worm shell (258) end bell nut essambly |2bA) into the rack piston (35) bore. As the bat nut approaches tha lerye bore, align the rcnical hie in the ball our with the threaded Jacsing screw (36) hole in the rack piston. SEE FIGURE 143. Stip bal nu int pistan boro unl tho bal guidus are held n place by the rack piston ard abaut 1 inch (25 ma} of ball nat is aut of the rack uistun, Remove the guide releining clip or ape ‘rum ball nut ened complete the entry of bal nut inlu rack piston bore, SEE FIGURE 144 Figure 744assemble locking 6, serew and washer NOTE stake lacking Ey washer WARNING NOTE WARNING position housing 38. in vise assemale 9. poppot adjusting screw Apply “Loctite Hycraulic Sealant” to the threads af locking eorew 196) and assemble lacking screw and the new lockng washer (SBA) ina rack vistay 1351, Pasitin the tals on the Incking wesher toward the ball nut end uf te rack visto}. SEE FIGURE 145, Torque licking serow 10 30-35 ft Ibs. (41-€7 Nm). 318 inch Alle socket ‘equred, SEE FIGURE 146, NOTE: The locking screw head and lacking washer will not racesserily be seated against the rack piston when serew is proerly torqued Stake Ihend up) the ralused sido oF the lacking ‘wesbor (GGA) firmly ageirst one fet of hex head on locking serew (36), Rernovs subassembly fm vise, SIE TIGURE 147 WARNING: IF THE BALL NUT LOCKING SCREW IS NOT STAKED CORRECTLY IT CAN BACK OUT AND HEAVILY SCORE THE CYLINDER WALL. THIS COULO RESULT IN LOSS OF POWER STEERING. NOTE: Allow “Loctite Hydraulic Sealant” 20 minutes to dry before adding cil to gear. WARNING: DO NOT ALLOW BALL NUT AND RACK PISTON TO ROTATE TO THE EXTREME: LOWER END OF WORM TRAVEL BY IT'S GWN WEIGHT WHILE THIS SUBASSENBLY IS NOT CONTAINED IN THE GEAR HOUSING, THIS COULD DESTROY THE SEAL PACKAGE AT ‘THE LOWER END OF WORM, CAUSING LOSS OF POWER STEERING IN ONE DIRECTION, Positan the housing (4) firmly in vie oo ir was ‘or dsassombly provedures, SEE MGURE 14, 1 poppet adjusting serew (431 hes been isassembied, apply clean grease or cil liberally 1y # new back up waster (101 and new U-rng (0A), Assembla now beck up washer then new O-ring ravetully ouy nur-threaded end af poppet ‘adjusting scraw end intw groove provided. SEF FIGURE 149, Figue 148 Figure 148, 45install poppet 40, adjusting scrow assembly assamble a adjusting screw nut grease seal and a. housing bore insert the Ag, assembled rack piston assembly position adeptor 44 ageinst housing NOTE assambie adapter 45. bolts and washers 4 Insta and turn ponpet adjusting sore (48) asiembly ito the hole provided in housing (471 leaving .88 inch (22 mint of exposed esting serew thread. SEE FIGURE 180, Ascamblo rut {49} onte exposed adjusting screw 1481 finger tight, Final adustrignt to Ue ede lotr. Apply © generous amount of clean grease ta the Teflon piston ring (344! ar cast metal ving [34h on assemble reek psn ad 16 the housing rack piston bore. SEE AIRURF 161 Insert the esserbled rack siston 196) into housing (47) and position rack teath 12 be waite through te sido saver epening and the peppet 123) ir Ine with poppet adjusting stew (46), As the rack pistor enters the noasing hore compenss piston ring (84] ur (24AI with your fingers and work the rack. piston inco the assomtied positn, SEE FIGURE 152, Alon the balt holes and ail transfer hole in the avaplor (201 with the oot halos and al ransfar hole in the geer housing 147), The goppet adjusting serew (91 7 the adaptor must align with poppet Id) ond seal ring 119) and 121) rust be in place, Hemave tape tram worm shalt servetions and rotate worm shett it required to position cantar against housing; SEE HGURE 158 NOTE: If @ line was scribed acrass these components before disassembly you cen now utilize the line to align these components. Assemble four bol's {2UA) with washers (200) ‘through adeptor 120) inta housing 14/1. Lorque bolts to 70-00 ft. tbs. (95.108 N ml if dry or 47-57 Th tbs. (64-77 N mul if ubriented. A 3%6 inch scokst required. SEE FIGURE 164 NS = eet | « Figure 160 Figure 1b4assemble a, adjusting screw and retainer WARNING grease side a cover bearing CAUTION NOTE CAUTION If the adjusting serew (45) has been reviuved fiom the sectar sheft 1451, clamp the sector shal into a soft fared vise hy gripping the sesreted ‘id. Coat tha expanded and af the new ecjusting sorew witl # sultable grave of whee! bearing qrease and insort into teress in endl of snetor sill. Thread & new sector shaft screw retainer 4) intu the sector shalt and adust ta permit trae rotation of savior shalt aujusing scrowy by hand without geroepuible end pay L000 to .002 in, C5 mint tense), Stake the new retsiner ina the two slts provided using suiteuls punch end aan check ‘reedor of acjustiny sunt mavement and end play. SEE RCURE 156 WARNING: USE CARE IN SECURELY STAKING ‘THE RETAINER (44) INTO THE SECTOR SHAFT SLOTS, A RETAINER THAT IS BROKEN OR CRACKED QURING THE STAKING PROCEDURE MUST BE REPLACED AS IT GOULD RESULT IN THE SECTOR SHAFT NOT BEING RETAINED AND THE LOSS OF MANUAL AND POWER STEERING CONTROL. Juply 4 yoteraus amcunt of elzan wheel bozring greese (do nol substitute anther type a grenstl Tw the beeing in side cove 98), SEC FIGURE 1b. CAUTION: Use only wiveel beating grease. This bearing is sealed end wil receive no lubrication from the hydraulic fluid in the gear. Without whee! bearing grease, the bearing could weer prematurely. NOTE: if the service replacement Tefian backup washer (42) is not an integral part of the service replacement seal (43), so alternate service construction on oxploded assembly foldout paye, examine the lead-in chamfer or radius on the side cover (short) end of sector shaft (46) bearing diameter. SEE FIGURE 157. if rough edges can be felt by drawing a thumb nail ecross the loadin ‘chamfer or radius on the end of sector shaft, skip procedures #48, 449, 450 and follow Procodures #51, #52, #53. CAUTION: Following procedures #48, #49, 4#50 with the sector shaft that dees not pass the “thumb nil test”, and a replacement seal (43) that dogs not have the Teflon washer (42) integral to it can tesull in the seal being destroyed when assembling sector shaft inte side cover. Figure 166 Figuie 165, Figuve 157 1assemble side 18, cover seal pack CAUTION WARNING assemble 4 rotaining ring install sector 0) shaft into side cover assemble steel at and Teflon washers into side cover assemble £2, retaining ring and seal CAUTION a ‘Assarble the stool becleyp washer {41} inta side covet (981, Asseriule a mew Teflon washer [42} then a new twa piace seal (44), ur a new two pioca soal (42/43) that has the Teflon washer incegral to it, into the side cover, such thet the ‘words “Cisida" are visible aiter the see! is assembled, SEE HBURE 158. CAUTION: Be sure thet a separate Taflon washer (42) is not used with e service two piece seal (42/43) that has the Teflon wesher intagral to it, WARNING: THE WORDS “GIL SIDE” MUST BE VISIBLE ONCE THE SEAL IS IN PLACE. OTHERWISE, THE SEAL WILL NOT FUNCTION, WHICH COULD RESULT IN & LOSS OF POWER STEERING ASSIST. Assamtily the side ener reteining ing 1438) int the ving groove uf the side cover (98), SFF HGURE 168, Apply a generous snoupl of elem grease ta tho short heoring eran of the sector shaft HBL, Inger ‘he sector shatt carefully into che side cover (28h Srrow in the seeiot shalt aqjusting screwy (451 caster clockwise in the side caver wail the sew reaches soil sight. Then, rotate tha adjusting serew clatkiwise nne turn, so thet the ‘de cover will rotate freely an the sector shaft SCE FIGURE 180. Ga to prnencura 24 If the replacement Tellon wesher {¢2 is not an integral part of the two piece seel (431 and the sector sit {48} did nut pass che “thurrb nail test”, assemble the sted backup washer (41) anc than the new Teflon wzsher 142) into the side caver (361 bearing bore, SEE FIGURE 161, Slide retaining ring 142A) onto the sie enwer ened of sector shalt 46), Assemble the new two pioce seal (43) onto the ond of tha suctor shaft about inet (25.4 min), The words “Oi Side” on the seal must face taward the sector shaft, SEE FIGURE 102 CAUTION: Be sure the two piece seal remains correctly assembled and that the vent plug (388) has been removed during these procedures. Figure 13 Figure 160 gure 162install sector 58, shaft into side cover install jam nut bf assemble vent plug £5, WARNING instal site 56 cover seal ring center rack 9, piston WARNING Be sure the sic cewer hearing, the sector shat bering diemeter and seal ara well greased, then insert sector shall (46) assembly ina tho sida cover (38) beating for ebout 8 tus af the adjusting sorew M5), Slowly and carefully work tha two pioea soal (43) down (he sector shelt ‘and squarely imo the sige cover unl itis past the retaining ring groove. Than work the rutaining ring {4341 into the retaining ring grove, Use ent ‘anproprite blunt erd punch or punahes, SEE FIGURE 163. Corafully turn the agjusting eoraw (45) through site rover until it reaches sold hight then hack sernw ore turn, so that the side over rulates freely an sector shaft Ingwall the seotar staft adjusting serew jam nut [37] onto the sector shaft adjusting seraw 145) @ few threads. Final adjusiment will be made later. SEE AGURE 164. Press @ new vent pluy (00) inw the hole provided in the side vover 138) uni Ue wlug is fs. SEE FIGURE 163. WARNING: DO NOT WELD OR OTHERWISE PLUG THIS HOLE IN ANY PERMANENT MANNER. THIS IS A SAFETY YENT WHICH FUNCTIONS ONLY IF THE SIDE COVER SEAL FAILS. IF THE SEAL FAILS AND THE PLUG CANNOT VENT, THE STEERING GEAR MAY LOCKUP OR OTHERWISE MALFUNCTION. Auply een yrease 10 The now side enuar seal fing (6), and assemble it anta the side ever (38l, Apply enoush qieese to hold the sea sing n slace, SEE FIGURE 186, flowte the worm sholt [25B} until the siring mark that is at the center of the rack piston (96) isin the conter of sectur shaft yzening in housing (471, This wil weoter the rack piston, SEE FIGUNE 167 WARNING: IF THE RACK PISTON IS NOT CENTERED WHEN SECTOR SHAFT 1S INSTALLED, GEAR TRAVEL WILL BE SEVERELY LIMITED IN ONE DIRECTION. THIS COULD RESULT IN AN ACCIDENT. Figure 18k \ Figure 16/ 9ingtall sector 5, shaft and side cover assembly NOTE NOTE CAUTION install side 59) cover bolts install trunnion 8) cover wesher and seal CAUTION WARNING 50 Remove any old tape fram sector shatt (46) serrations and ayply ove layer of new ten te shall serratinns and boll groove, Install sector holt end sid cover assembly inta housing 1471 The sector shatt center tooth space or taath as indicated by the timing merk on the end ot sector shaft must engage the rack piston (31 center teath or tnath space as indiratad by @ timing ‘ark on the rock piston. SEF AGURE 168 & 160 NOTE: The earliest model HFB4 steering gears wort manufactured with a sector shaft tooth and a rack piston tooth space in the center of travel position. NOTE: If there is not a timing mark on the end of sector shaft (46) add a timing mark before assembly, with chalk or markirg pencil on the end of the sector shatt inline with the conto of the center tooth space or canter tooth, whichever is central on your sector shait. CAUTION: Be sure seal ring (39) is in place. Install the six spesiel side oover bolis [3MAL ito the side cover and torque them 4 160-171 ft Ibs. 1200-290 Nm) if dry or 198199 ft. Ibs. 1146-174 M1 on) if lubricated. 10/16 incl sockot required. SEC FIGUAE 170, Place the trunrion ever 182 exterior fare down 9-4 besch and instell the naw Teflon backup washer (421 ad then the new twa niece seal (43) ar thn new two pieen saa) 147/43) that hs the Toflan washer integral ta i. The words "Cil Side” tn the see) must he visitle after assembly. SEE TIGUACS 171 and 172. CAUTION: Be sure that a separate Teflon vweasher (42) is not used with a new service ‘two piace seal (42/43) that has the Tefloa ‘washer integral to it. WARNING: THE WORDS “OIL SIDE” MUST BE VISIBLE ON THE SEAL AFTER IT IS IN PLAGE, IF NOT, THE SEAL WILL NOT FUNCTION, AND A LOSS OF POWER STEERING ASSIST MAY OCCUR. Figue 172install seal ring instell trunnion cover and screws assemble sector shaft protector seal assemble worm shaft protector seal i 02, ta. Grease the new trunnion cower seal sing 161) and instal it into*the. trurnion cover (62) seal ring ‘grove, ack sel atwa of secror shat (49) with clean tigh ‘emparatire industiid grease per Rase saeieation 45231, Mobil temp 1 or 2 or equivalent. Install 1¥e trunnion cover 182). SOL FIGURE 173, Install the four union cover sores (7A) and torque them to 1328 {bs (BAL Nm) if dry or 11-16 H, bs, 15:22 Nin) if lubricated. SEF FIGURE 174, Remove tape rom the sector yhall serratuns, Add mora ot the special grease 10 the cupped side of seal [O3} and assemble ore’ sector shatl (46) and trunnion cover (42), SEE HILURE 175, Adie she snetial qreese 10 supped sde ot protector spol (1] ond ossemble seal aver worm shaft 1256) and upper caver (7). SFE FIGURE 178 This completes assembly af the HFC steering gear. Before you instll the gear cma the vehicle, make final anjusimams desribed nn page 82, AL paris should be plugged until unit is installed in wick, 5inal Adjustments center steering 1. Tet certer the Sivering gear, rotate worm shaft gear (25R) unil the timing mark on the end cf sector shaft 196) is germendilar to the worm shat SEE FIBURE 177. A 12 point 2! ar 13016 inch tox end af socker rete NOTE NOTE: Worm, valve thrust bearing preload adjustment was accomplished in assembly figure 177 procedure 11, page 38. tighten 7. Tighten sector siaft agusting serew (451-10 adjusting serew provide 15 20 inch Ios. (1.72.2 N inl uf torque required to rotate the worn sell {2581 theaugh 90° wach side ul center, SEE FIGURE 178, Nore NOTE: This procedure will properly mest and seat the rack giston teeth and sector shaft tooth for final adjustments. Figure 178 loosen 3. Loasen sector shatt adlusting scresw [451 one turn adjusting screw and neve masimum torque required ta ratace the and note torque worm shof: (263) through 181° oach sida af canter adjust 4, Adjust sectar shots adjusting screw (48) 19 adjusting increase maximum torque noted in procedure #3 screw by 2 tw 4 inch Ibs, (.28 tu .26 Nm), Torque jer rut (371 using @ 3/4 inch socket, lo 4045 MIs (E487 NV al and check worm shell toraue auain Raadjust it worm shatt torque exceeds 15 ineh Ibs, 1.7 Nm This complotes the final adjustments of the HEB! gear ta he made before itis instal into the vehicle's steering system, lstal the gear by folowing instwuctians in the vehide shop manual. Then lalow the suezeeding soctions at this servis menval (HFBA on "HYDRAULIC FLUID" and “FLUNG AND AIR ULEEDINE |HE SYSTEM” which also includes instructions for edjustan. af the adjustable poppot valas.Hydraulic Fluid Keep Ue sieering system filed with one of the following fils AUTOMATIC IHANSMISSION FLUID TYPE “L" ur *F* FORD SPEC. M2Ci99C AUTOMATIC TRANSMISSION FLUID DEXRON II SHELLHUTELIAT ..... SAE aU mooie = SAE 1030 ASHLAND SAE Iwan) UNION i SAE TOWN) TEXACD SAE 1040 ine . SAE Iowan WARNING: COMPLETELY FLUSH THE STEERING SYSTEM WITH ONE DF THE RECOMMENDED FLUIDS ABOVE ONLY. DO NOT MIX OIL TYPES. ANY MIXTURE OR ANY UNAPPROVED DIL COULD LEAD TO SEAL DETERIORATION AND LEAKS. A LEAK COULD ULTIMATELY CAUSE THE LOSS OF FLUID, WHICH COULD RESULT IN A LOSS OF POWER STEERING ASSIST. Filling and Air Bleeding the System CAUTION: For steps 1 and 2, do not turn the steering wheel. Otherwise, air may be induced inta the system. 1. ll the reserve nearly full. Crank the engine for 10 seconds without, if possible, allowing it 10 start, II the engine does start, shut © dome immedistoly, Crock and refill the veservoil, Repeat al last three iimes, each time cheskhg and refiling ihe reservar CAUTION: De not allow the fluid to drop significantly or run out of the reservoir. This may induce air into the system. 2. Start the engine ard Int ir idla for 2 minutes, Shut tho enging off and check the fluid level inthe reseruir Stort the engine again, Steer the vive fron full eft w full ight tue several tines Add tud, as necessary, to the fil ine an the cipsik NOTE: Popnets, equipped on the gear, must be adjusted so that they relieve pressure at full lft and right turns to aid ia the removing of air fram the system, At this time, make sure any poppets are properly adjusted. If they are not, adjust them in arcerdance with section 4 (page 19) and repeat step 3. iaWarnings for Proper Steering Gear Operation WARNING: DO NOT WELD, BRAZE OR SOLDER ANY STEERING GEAR OR SYSTEM ARM COMPONENTS. WARNING: MAXIMUM FLOW UNDER ANY CONDITIONS MUST NOT EXCEED VEHICLE MANUFACTURER'S SPECIFICATIONS. WARNING: MAXIMUM OPERATING PRESSURE MUST NOT EXCEED 1750 PS! (120.7 bar) WARNING: ALWAYS CAREFULLY INSPECT ANY STEERING COMPONENT WHICH HAS BEEN (OR 18 SUSPECTED TO HAVE BEEN) SUBJECTED TO IMPACT. REPLACE ANY DAMAGED OR QUESTIONABLE COMPONENT. Steering System Maintenance Tips —Prevent internel haitoming of the steering gear. Caretully check axle stops to be sura that they meat the manufarturar’s spacificatinns —Rogularly chuck the fliié and the fluid lovel in tha pawer steering reserva, Keop tims infleted ta correct pressure bla use a puller, ever hammer a trch, 10 rere ptman arms —livestigale end immediately correct the cause of amy play, ratile, er shimmy in any part of the steeiing linkage or steering mechanism Finmavn the couse af steering elim misalignment Encourage al drivors to report any malluretione or accidents thet could have damaged steeting components, —Du ut ational 10 weld any broken steuring component. Rualace the eoraunene with orignal emuizmient on. —Dn not cold straighten, hot straighten, ar bene any sieering system companent —Always clean off around the reservoir fillet cap before you remove it, Prevent dirt or thor forcign mattar from entering the hyurauie systems. —hvastigate end correct any extemal leoks, nm mattar how minor —Replace fiters and pumgs in eomplanee with specication —Ii extendlad stationary use of vebicle's developing excessive hydraulic Mid temperetures consult vehicle manufacture for auailary couling meio Maintain grease pack applet tehind the input and output soft's protertor seal e3 0 general maintenance procedureTAW Automotive Cuaramacn'al 8: 200 Hoath Stree: Lefayetty, 1M «7aq¢ Tel 785.423.3977 Fax #85409." a60 Hy ova va comfsommercialsiceng