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    47 views69 pages

    Sheppard Manual 92 Series

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    aditya

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    © All Rights Reserved
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    Sheppard POWER Sulde R. H. SHEPPARD CO., INC. ® 101 PHILADELPHIA ST. HANOVER, PA 17331-0459 PHONE 717-637-3751 EASY LINK 910-3806532 FAX NUMBER 717-633-4125 nha SERVICE CATALOG 1000485 REV1 - 7/12/96 SHEPPARD POWER STEERING SERVICE MANUAL How to use this manual. ‘This service manual will contain information covering all current and past model Sheppard Power Steering Gears. The Sheppard Short Series Steering Gear is used as the base line and carlicr and later production models will be covered in this manual as variations. Use the identification guide to determine which particalar Sheppard Steering Gear you are working with. Follow the dis- assembly, cleaning and inspection, and repeir procedures inthis manual using the variation(s) procedures s they apply to your steering gear. INDEX Page Operating Principles 3 Model Identification .... 67 Parts Identification ...... 8-13 Lubrication ... General Diagnosis cca foes 15-21 Hydraulic Supply Diagnosis penetra Oil Flow Requirements 24 Disassembly .. : 25.29 Cleaning & Inspection i 30 Repsir ... 3131 Reassembly cscs i eneenees 5253 Integral Relict Valve ovine S458 Pitman Arm Installation 5637 Bleeding System 38 Relief Valve Plunger Adjustment sesssesteeees 58259 Dual Integral Gear Systems - 60-62 Torque Specifications .. 8 Fixed Miter Gear Repair -.. eos ceveseee 64-69 Swivel Miter Gear Repair 70-73 “T" Box Miter Gear Repair eesnsee TET4 Special Tools - 75-16 Page 1 ‘“ACOW LVHE OL SaTWdaV J“ SALVNOISAC TEGOW WAGNA ~X. SHEPPARD POWER STEERING SERVICE MANUAL SS <= Seen = eee = + Bape + rs Perec re | 2aaos Soa Sencaneaneen © i+ = x ¥ ¥ 7+ = x <—e — — ¥ — z x Page 2 SHEPPARD POWER STEERING SERVICE MANUAL DESIGN ADVANTAGES YOU GET WITH STATE OF THE ART SHEPPARD INTEGRAL POWER STEERING Zz NEUTRAL POSITION 1. Dependable an trouble sie service. ADJUSTABLE STOPS prevent damage and sancessary wear, When wheels a fumed to a detsbleexteme in eter diction, adjustable Stops automaticaly unload the complete hydalic system. “This all part of the steering mechanis ae protected from undsestess and damage. Oil inthe bydalic sytem is prevented fom ovetheating, Service life of bth pump and Byers valve ar profonged. 2 ass responsive steering control. With Sheppard integral design there is only ONE HIGH-PRESSURE LINE from pump to gear. This elimintes dri and mushy stering nse by the swelling and breathing of complex of extra pressure lines between separate valve, pump, cylinder snd geo. 3 the sieppard unit i mosnted similar tthe mecheica stsrng gear. Accidental snagging and damage over ough tern i avoided because GEAR DOES NOT PROTRUDE below fame INTEGRAL RELIEF VALVE 4 ais wear is negligible because here are ONLY 4 MOVING PARTS. 5 wit sheppard inter design, seving seponse isin melate and precse heease the CONTROL. VALVE IS LOCATED WITHIN THE PISTON. This eliminates spingy Iyaulepessre Ins that can cause lag and hesitation. G in event of nydraviic matfonction, BUILT-IN ME- CHANICAL STEERING sllowe for safe contol of the vehicle. 7 WTEORAL PRESSURE RELIEF VALVE inset in the Piston, An optional pressure relief valve is available which fits the maximo pressure in the steering system. This feature wil avoid rapid temperature build-up caused by 0 mal pressre relict and ofl recrelation within the pumping chamber or pump body Page 3 SHEPPARD POWER STEERING SERVICE MANUAL BASIC OPERATING COMPONENTS: 1. actuarmic SHAFT is conoces tthe sesring column 2, ACTUATING VALVE is conned within the piston and assembly is treaded wit aliavy Acne tend having mile teaded to accommodate the inp shaft, When he inp shat an tuned, te valve travels over shat teeaded aes. Two pos on valve ouside diameter contl oil low though the piston. The vate has linear enoton, peitng edges ofthe pot seat ‘gaint mating edges onthe nse ofthe piston. neurrac position 7 |/ 3. risrow isiocaed within the hosing. Ack on the pston Sector havouipt sha and pinion teh lcted ithe engages the pinion gear on the output shaft. Ports in the piston housings ture by the piston rack. This provides rotating action at fanetion for cither pressure or exhaust depending upon direction of the pitman arm connected to the stering linkage. valve tavel, The piston centers itself over the valve to provide steering ation. Page 4 SHEPPARD POWER STEERING SERVICE MANUAL OPERATING PRINCIPLES “The Sheppard Integral Power Stecring Oear provides full-time bydcauie steering which slight and responsive, Only sufficient manual input effort to overcome the reversing springs and close the contol valve to cause a pressure build-up is required. Full rated axle loads can be steered with ease. ‘The actuating shat (1) is connected tothe steering column and is thresded with an Acme type thread. (2) The actuating valve (3) i threaded to accommodate the actuating shaft and is centered within the piston by reversing springs. The valve moves ina linear motion within the piston permitting the edges ofthe valve to overlap mating edges on the inside ofthe piston. This causes high-pressure oil to build up at one end ofthe piston. Ths higher pressure on oue end of the piston causes the piston to move in the bore ofthe gear housing. The output shaft and pinion gear (G) are engaged toa rack gear (5) machined into one side ofthe piston. As the piston moves, the output shaft and pitman arm ae rotated by the rack and pinion gear and steering operation is performed, When rotation or inpat fom the actuating shaft ceases, pressure on, or movement of the aetueting valve stops and the reversing springs (6) atthe ends ofthe valve ceater the valve in the piston relieving the high pressure and power tothe steering ceases. Movement of the actuating valve, to contro il pressure is controlled bythe deflection ofthe reversing spring at tither end of the valve. Total movement of the valve is approximately .040 of an inch. Relief valve plungers (7) or adjustable stops are provided atthe beating eap and cylinder head. When the plungers are adjusted properly, they will automaticaly unload the hydraulic system if the wheels are tumed to either extreme direction, 3. 2 8 \Whea the engine is running there is constant ol flow through the steering gear at low pressure. This constant oil flow provides for instant response and absorbs road shock to help eliminate stering wheel kick and protect the steering gear. Pressure is equal throughout the steering [gear and il cooling and lubrication are essured. Care should be used in towing or moving a vehicle where the engine or hydraviie supply pomp are inoperative. In this instance the. ability of the steering gear to protect itself is reduced and mechanical damages can be encountered ‘An optional pressure relief valve integral wit the steering gear is avilable onthe Series 5 & 6 Steering Gears. This valve limits maxinaum ‘ecting system relief pressure atthe steering gear, a point inthe scering system which is farthest from the supply pump, pamping chamber. ‘This effectively reduces system temperature by avoiding high-pressure by-pass and recirculation within the pump. “The Sheppard Integral Power Steering Gears have been designed to provide long service life and simple service repait. The rack and pinion gear set does not require adjustment. There is no centerpoint adjustment, The high-pressure sel atthe inpuvactuating shaft isthe only seal ‘which is exposed to high pressure and motion, unles the steering unit has the optional hydra max braking capability. With this option the ‘output shafvsector also has a high-pressure seal. The high pressure actuating shaft seal is protected by a drt seal and salt seal which axe seperated by a grease pack thats fushed during lubrication. The clearance between te cylinder bore and the pistons closely controlled, act ‘withthe series 6 steering gears, piston rings were added to efficiently uilize the hydraulic oil supplied from the power steering pump, With rasonable care and limited maintenance the Sheppard Steering Gear will provide many miles of trouble free and effortless performance. Page 5 9 S3I4¥aS vee SaaS YVID SAVIS 9 SSINSS: Page 1 yVaD JAVITS $ S3ISS SERIES 3 & 4 SLAVE GEAR ‘SHEPPARD POWER STEERING SERVICE MANUAL Symptom Possible cause i leaking at outpat shaft of steering gear Clogged oil filter in reservoir (high back il leaking at actuating shaft of steering gear Oil leaking at supply pump drive shaft Oil leaking between reservoir tnd pump body Lubricant milky or white in appearance il forced out of reservoir Engine Oil in power steering reservoir (Gear driven pump) pressure) Pinched or restricted oil return line Damaged quad ring seal Damaged bronze bearings Damaged lipseal (Series 5 gears) Damaged roller bearings Wom or damaged cil seal ‘Damaged actuating shaft seal surface Damaged oil seat (il seal-heat damaged Loose or damaged bushing on pump drive shafi Seal or gasket damaged Woter entry through reservoir venting systern Clogged oil filter Loose pump drive belts Air in system Faulty supply pump (Cavitation) Relief plungers of steering gear not adjusted propeely (Operating temperatures too high Faulty seal st pump drive shaft Faulty seal at accessory shaft driving supply pump Page 16 Remedy Replace filter Increase change frequency Locate and correct (Check back pressure Replace quad ring seal Replace Bronze bearings Polish outpat shaft or replace to remove bronze deposits Replace with replacement seal assembly Replace roller bearings Polish output shaft or replace to remove piting & grooving in seal area Replace seals Replace damaged parts Lbe bearing eap more often Replace oil seal ‘Check operating temperature Repair pump per pump service instructions Replace damaged parts (Clean vent system or replace cap assembly ‘Change oil and oil filter Increase change intervals ‘Adjust belts or replate ‘Bleed air from system ‘Check for air leak on suction side of supply pamp Check supply pump following “Hydraulic Supply-Disgnosis"” ‘Repair pump per pamp service instruction Aaust reli plungers (see final adjustments) Follow ““Hyéraulic Supply-Diagnosis™ procedures Repair pump Repair accessory drive SHEPPARD POWER STEERING SERVICE MANUAL Symptom Lubricating Oil discolored or smells bad High Operating Temperatures (lin Reservoir - Foaming [No power steering on cold start Excessive pump pressure with steering ‘gear in neutral position ‘Wheel cus restricted Erratic steering or no steering at all (Check supply system as detsiled in “Hydraulic Supply ~ Diagnosis" section) Possible cause Operating temperatures too high ‘Change intervals 100 long Tnconeet lubricant used Oil low restriction i flow too high {Air lea in sueton side of supply pump Pump cavitating Oil overheating Taconeet lubricant Hydraulic supply pump vanes not extending (Vane type pump only) Pinched oil return line ‘igh back pressure Binding storing column Damaged actuating shaft bearing Relief plongers misadjusted Insufficient volume of oil being metered by flow divider to steering gear induced by foreign particles on flow divider valve, causing the valve to hang up in the bore Flow divider spring takes permanent set because of fatigue, thereby, allowing flow divider valve to move easily and reduce oi! volume [Broken by-pass spring in flow divider Sticking pressure relief valve Page 17 Remedy ‘Cheek and corect cause of overheating Increase oll change frequency rain, fush and refill with 10W-40 motor oil ‘Check back pressure (see Hydraulic Supply — Diagnosis section ofthis manual) ‘Check maximum oil flow (see Hydraulic Supply — Diagnosis section) Refer to pump servicing instructions (Check for restriction in pump supply ‘See high operating temperatures Change to 1OW-40 moter oil Increase engine speed momentarily to extend ‘vanes and start pump action. Usually a temporary and infrequent occurrence and not cause for pump repair or replacement. Relocate tine ‘Repair steering colo Replace damaged parts as required Adjust relief plungers (se final adjustments) Polish flow divider valve to remove foreign particles and burrs Refer to pump servicing instructions Replace flow divider spring Refer to pump servicing instructions Replace with flow divider valve assembly, ‘which includes by-pass spring Refer to pump servicing instructions Repair or replace relief valve a5 requied Refer to pump servicing instructions SHEPPARD POWER STEERING SERVICE MANUAL Symptom Heard Steering ‘Wheel steering hard in one or both dizections ‘Wheel stesring hard in one direction Steering extremely light in one or both direction Possible cause Loose belts ‘Wom pulley(s) due t belt sipping Faulty supply pump ‘Front axle overloaded ‘Faulry steering geomerry High operating temperature ent or damaged king pins and tie rods, Front end load too great for rated axle capacity ‘Fatigued by-pass valve spring in pump Low oil level in steering system Air in system Caster and eamber degree incorrect Metal or foreign material caught in actuating valve. ‘Actuating valve worn or chipped by dirt, Broken reversing springs in steing gear ‘Metal or foreign material in relief ball seat in piston of steering gear Foreign material in relief valve ‘Bent or damaged reversing springs Remedy ‘Tighten or replace belts Replace pulley(s) and belts (keep belt tight) Follow “Hyéraulie Supply — Diagnosis” procedures Refer to pump servicing procedures ‘Comect loading practices Align front end Locate and correct cause of overheating Repair or replace king pins and tie rods Refer to servicing instructions Lighten load or install larger steeting gear Replace with flow control valve assembly Refer to pump servicing instructions Fil oil reservoir as required See “ Lubrication" Bleed system and check for cause of air (See final adjustments) Conect to “Specifications” Remove actuating valve ‘Clean and check parts for damage If damage is excessive replace damaged parts as required Replace reversing springs and damaged parts Refer to repair procedures to check for ‘déitional damage Remove piston and clean relief valve seats or replace damaged pacts (Clean relief valve ‘Check for impact or secident damage Replace damaged parts (see “Inspection” Pecagraph) Page 18 SHEPPARD POWER STEERING SERVICE MANUAL Symptom Possible cause Remedy Stering input not smooth (sizing, ‘Wom universal joint Check and replace as required binding) Lack of lubrication Lubricate per vehicle manufacturer's recommendations Universal joint not phased propenly See paragraph last page this section Low oil flow Tae speed t00 siow Drive belts siping Supply pump not to specifications (ee “Hyérablc Supply ~ Diagnosis) Pump cavitating Correct pump supply Overheating Comect cause of overheating Daxting, wandering (overstering) (011 flow to high Supply purnp not o specifications (ee “Hydraulic Supply ~ Diagnosis”) Ale wapped in steering gear Bleed system (se final adjustments) Looseness, worn front end paris (Chock and repair as required Front end alignment not comect ‘Align frontend ~ Caster Rail tre sidewall flex Chock re pressure (Check for out of line tread Contact tre manufacturer representative [Excessive wear or damage in string gear Check and repair as required Overloading Reduce loads | ‘Stooring column u-oint phasing incorrect See note end of this paragraph Mechanical bind in steering gear (Check steering gear mounting for distortion (Chock for damaged or distorted steering gear ‘components ‘Tight tie rod ends & drag link sockets Check rotational torque & replace if necessary ‘Note: Universal Joints ‘Universal joint are designed to operate best when the angle between the drive and driven shafts is « maximum of 20 to 25 degrees. Angles {greater than ths will eaute undesirable velocity changes between the two shafts. This velocity change may upset steering performance. When two universal joints are used, itis in most instances possible to phase the two joints to match ahigh and low velocity ina manner thet will pro- ‘vide equal velocity between the drive and driven shafts, A third universal joint in the shaft amangement can upset the phasing ofthe first ‘two joints and i i important tht cis third joints operating angle is Timited to & maximum of 20-25 degrees. ‘Phasing of the universel joints inthe stering column can be checked quite easly. Using an inch-pound graduated dial reading type torque ‘wrench, read the variation inthe torque reading while steting from lock-to-loc, with a socket on te steting shaft nu udder the hom button, Variation of more than 15 in.-Ib. indicates improper phasing. This reading is taken with the vehicle stationary and the engine running Phasing can usually be accomplished by rotating the two piece intermediate shaft one spine ata time until the torque reading remains the same all the way around the 360 degree rotation of the steering wheel. Page 19 SHEPPARD POWER STEERING SERVICE MANUAL ‘Symptom Excessive backlash [No attempt to retum straight ahead from turns Possible cause ‘Worn universal joint ‘Wom pins and keys universal joint to actuating shaft and universal joint to oering shaft Low oil volume Pitman arm ball worn “egg-shaped” Jmproperly adjusted drag link, pitman sem to dag link and steering arm to drag link Loose bracket frame to bracket or bracket to gear ‘Rack on piston damaged Damaged pinion gear on output shaft Damaged output shaft splines ‘Worn output shaft bushings ‘Worn pitman arm splines ‘Worn actuating shaft and valve threads Free play in miter gears of angle drive Damaged reversing springs Universal joint yoke loose on actuating Shaft [No positive caster Steering column bind Steering gear mounting distorted “Linkage ball sockets seized or binding Page 20 Remedy Replace universal joint ‘Replace pins and Keys Check flow divider and pump drive belts Replace pitman arm assembly where riveted ball is used or only where bolted ball is used (vertical socket) ‘Agjust drag link, drag link fo pitman arm and drag link to steering arm Romove bracket, clean frame and bracket check radius of frame making sure bracket is not bearing on radius surface Check bracket for wear from working Replace bracket and tighten to recommended torque rating according to size and grade of bolts If necessary, replace bracket with new one Replace parts as required Replace pinion gear Replace output shaft Replace bushings and polish shalt to remove bronze deposits Replace worn parts Replace worn parts as required Follow “Hydraulic Supply Diagnosis” ‘procedures to locate cause of wear ‘Remove miter gear housing shims to mesh ‘gous ‘Check and repair as required [Repair or replace dameged parts, check for spline wear Set to 4 to 6° postive caster ‘Check and repair U-jints and support bearings Shim mouating pads to correct piston 10 bore interference (Check and repair or replace SHEPPARD POWER STEERING SERVICE MANUAL Symptom Possible cause Remedy [No attempt to return straight ahead King pins seized or binding Repu or replace from turns (cont'd) Knuckle clearance misadjust Adjust clearance to specifications (Oil low rate incorrect (Check ané correct supply pump or controls Note: ‘Acme thread weer generally comes from inadequate lubrication or excessive manual steering of the vehicle. Mana steering results from ‘inadequate pump pressure or flow, or an overloaded front axle where you need steering forces in excess ofthe hydraulic design ofthe steering sear Note: Freeplay ‘The movement of the shuttle type actuating valve within the piston, slong with the normal clearances required between operating parts in the steering gear will produce a certain amount of unresponsive motion atthe rim ofthe steering wheel. This unresponsive motion is inherent tothe esign and must be considered normal. With recent advances in echnology and manufacturing methods it has been possible to considerably reduce the amount of this unresponsive motion. Steering gears in service prior to July 1978 could be expected to have 3% to 4 inches ‘unresponsive motion, Curreat production Sheppar steering gears in service will have 1% to 2% inches of unresponsive motion. Various ‘combinations of steering gear ratios and stering wheel diameters could effectively reduce these maximum allowances. Nominal unresponsive ‘motion in Series 6 steering gears, measurable at Ys to 1 inches Unresponsive motion is measured at the rim ofthe steering wheel. It must, therefore, be noted that aay freeplay in the stering column and related components will affect your measurement. The steering gear mounting must be tight ad steering linkage wear adjusted out or worn parts replaced. ‘The vehicle shouldbe standing on a smooth shep floor with the engine idling when unresponsive motion js checked. Measurement is made at the tim of the steering wheel, from initial tie and wheel movement left ster, to intial tre and whee! movement right steer, Page 21 SHEPPARD POWER STEERING SERVICE MANUAL HYDRAULIC SUPPLY — DIAGNOSIS ‘The Sheppard Integral Power Steering Gear is dependent upon adequate supplies of oi pressure and volume of ol flow to enable the steering gear to operate as designed. Oil pressure seacting on a piston creates the force to cause the piston to move and assist steering effort. ‘As the piston moves itis displaced in the cylinder bore by a volume of ei under pressure. How fast the piston can be displaced is dependent upon adequate oil flow ard volume. Oot pressure and oit flow requirements are engineering considecations that arc established during the design of « total power steering installa- tion, When diagnosing power steering problems you must be able to determine that oil pressure and oll flow meet design specifications, Pres- suze and flow specifications vary considerably and the vehicle manufactuet’s recommendstions must be followed carefully at all times. Back pressure and operating temperature aro two additional factors that must he considered during the diagnosis of power steering problems, “High back pressures will restrict the moverneat ofthe piston inthe power steering gear and this back pressure must be overcome before stoct- ‘ng power is available. Back pressure is caused by restrictions to oil flow. A clogged oil fer, undersized {ings and lines, pinched lines and high flow rates are possible causes of back pressure. High system oil temperatures reduce the overall efficiency of the steering pump and the steering gear. High temperatures are caused by re striction to flow or inadequate system oil capacity to allow for heat dissipation during normal operation. A supply pump which constantly ‘operates at maximum pressure relief will also generate more heat than can be dissipated ‘Various types of pressure gauges and flow meters are available and can be used to diagnose power steting problems. A pressure gauge which reads atleast 3000 PSI and a flow meter with a capacity to 10 GPM are used to cheek pressures and ol flow. A. shutoff valve downstream fiom the pressure gauge makes it possible to isolate the steering pump from the steering year and by closing the valve, maximum pump relief pressure can be read, A simple thermometer in the reservoir will indicate system oil Temperatures, "Tho gauge sot illustrated will indicate pressure (PSI) and flow (GPM) with a single connection in series with the high-pressure line tothe steering gear. A shutoff valve is included oa HYDRAULIC SUPPLY—DIAGNOSIS PAGE 2 ‘Using the equipraent available to you, proceed with your evaluation ofthe hyckavlic supply system. Refer othe diagnosis chart for farther assistance. 1, Make necessary gauge/meter connections 2. Star engine and check system oil level assuring that oil flow is in proper direction through the low meter. 3, Place thermometer in reservoir, 44, Rum the engine at correct idle speed and ster from lock-to-lock several times to allow system to warm up. (140 to 160 degrees F.) Page 22 10. SHEPPARD POWER STEERING SERVICE MANUAL ‘Pump maximum pressure relief With the engine running at specified ide speed, slowly tur the shutoff valve until closed and read the pressure at which the pressure relief valve opens. (Open the shutoff valve as quickly as possible to avoid heat build-up or possible damage tothe steering pump.) ‘This pressure reading should equal the maximum pump pressure specified by the manufacturer of your chassis. Check your specifications ‘Caution: A malfunctioning pressure relief valve may not relieve pump pressure and closing the shutoff valve may cause severe pump damages or high-pressure hoses to rupture, Constantly observe the pressure gauge while closing the shutoff valve. If pressure rises rapidly or appears to be uncontolled do not completely close the valve before inspecting the pump and pressure relief valve. Flow Test — Minimum Recommended Flow ‘With the engine running at a specified idle speed, vehicle stationary on the shop floor and with anormal load on the front axle, steer the ‘wheels from full right to full let tara and observe the flow meter. The flow must not fall below the minimum GPM flow specification Note: It is important that flow be checked at normal operating temperature and with load on te front axle, or steering respouse com: plaints may not be found. Inadequate flow will cause binding, uneven or intermittently hard steering. Flow Test — Recommended Maximum Increase the engine speed to approximately 1500 RPM and note the flow rate with the stering whee! stationary. Check this reading ‘against the maximura flow rate specifications. Excessive ol low can cause high operating temperature, and sluggish heavy steering response. Back Pressure ‘Normal system back pressure will be 50 to 75 PSI withthe engine idling andthe steering whecl stationary. Back pressure is checked withthe system at normal operating temperature 1. Operating Temperatures ‘Steering system oil temperature is best checked after two hours of normal operation. Ideal operating temperature should range between 140 to 160 degrees Fahrenheit. Normal operation inthis range will allow for intermittently higher temperatures which will be en- countered during periods of heavy steering usage. Aerated Oil Visually check forthe presence of ar aixed withthe ol in the steering system The oll shouldbe clear. Any signs of frothing indicate air eniry and steering performance will be affected. Carefully check for leakage on the suction side ofthe steering pump. Drain and refill the system and bleed for air following the procedure under final adjustments. Before any steering gear repairs are attempted the above hydraulic supply evaluation must be completed and corrections made as re- aquired. Many times steering gears have been repaired or replaced needlessly because a hydraulic supply system evaluation had not been made. Additional references to pressure and flow testing will be made in the diagnosis chars in the “*General Diagnosis" section of this manual Page 23 SHEPPARD POWER STEERING SERVICE MANUAL OPERATING PRESSURE & OIL, FLOW SPECIFICATIONS ‘The. H. Sheppard Co, Inc, manufactures two series of stering gears. A low pressure series designed to operate inthe range of0-1300 PSI and « high-pressure series with desig capabilites to 2000 PSL. Each vehicle manufacturer specifies the maximum operating pressure at ‘which their various steering installations are to be operated. Refer to your vehicle manufactures's specifications for coreet relief settings for teach of your vehicles. Do not increase the maximum operating pressure without consulting the vehicle manufacturer or serious damages can be encountered. il flow for the Sheppard steering gears ate outlined below by Model number. The indicated Model numbers correspond with the Mode) number cast into the steering gear housing. Oil flow requirements remain the same for al similar Models and do not change from installation to installation. Follow the O.E.M. Truck Monufacturer’s recommendations. Low Pressure Series (Obsolete Production Models) Model wel LSD Oil Flow (GPM) USS. ‘Minimuns* 19° 22 36430-4857 Maximum 24 27 44 53 60 70 High Pressure Series (Obsolete Production Models) Model 192 282 372,382,352 il Flow (GPM) US. Minimum* 22 32 36 Maximum 27 50 50 ‘High Pressure Series Model 2DALL «RAL 492 ALL $92 ALL. il Flow (GPM) U.S. Minimoum® 32 3.6 43 51 Maximam 50 50 60 10 High Pressure Series 6 Gears Only ‘Model 29286 39286 Flow (GPM) U.S. ‘Minimum* 29 33 Maximum 5.0 5.0 ‘High Pressure Series Dual Systems Model 292W/292 Slave 372-382W/292Slave 392 W/392Slave Ratio Low = High Low High Low High il Flow (GPM) U, ‘Minimam* 45 40 5.0 43 50 45 Maximum, 55 8.06.0 33 60 55 Model 392wi292Slave 492W/492Slave _592W/592Slave Ratio Low High Low High Low High Oil Flow (GPM) US. Minimum* 500 45 65 60 8S TS ‘Maximum, 60 ss 15-710 (9838S "Minimum flow is checked at operating temperature while steering from fall lft to full right withthe engine at ide. ‘To determine iow or high ratio, disconnect the master gear drag link, tam the stering whee! frem full et to ful right and count the number ‘of tums, If total turns is 5 or less the ratio is low. Over 5 tums is high ratio, Page 24 SHEPPARD POWER STEERING SERVICE MANUAL DISASSEMBLY Review your diagnosis ‘The diagnosis section ofthis manual has been placed inthe front ofthe Sheppard Power Steering Service Manual to emphasize the importance of proper diagnosis. Repair time and down time as well as total repair costs can be reduced if needless disassembly and steering gear pats replacements can be avoided. Before removing the steering gear from the chassis you must be certain thatthe hydraulic supply system is operating correctly and that all mecheniesl components are in good repeir. (Caution: The Sheppard Integral Power Steering Gear isa precision machined assembly and care must be taken during repair to keep it free of dirt and foreign material. All intemal parts must be handled carefully to avoid damages to machined surfaces. Nicks or burrs can cause damages to mating pars and must be removed with a fine hand stone before reassembly. Working on a soft cardboard or plywood surfaced ‘workbench is advisable. Follow disassembly procedures as required. 1k may be necessary on some installations to remove the pitman farm before the secring gear is removed from the chassis. In all, ‘cates, it is important that a suitable puller is used when the pitman am is removed. (Snap-on puller P/N CG 283) ‘The pitman arm may be located on the output shaft by two socket head retaining set screws, a self locking aut, or by a split nut and ‘ap screw arrangement. ‘Caution: Do not pound on the pitman arm or apply excessive ‘eat as damages to the pitman arm or output shaft could cause a serious accident at a later date. Welding of the pitman arm and shaft must be avoided at all times. $16 Page 25 SHEPPARD POWER STEERING SERVICE MANUAL ‘The pitman arm may also be drawn onto the tapered spline of the ‘output shaft with @ one-piece retainer, with or without tab washer (Gee photo $-22). The early 592. steering gears used a similar installation, however, it was of a two-piece design. See below. 6-23 -$.24) To remove the retainer, @ short piece of % or % inch hard stee] hexagon stock is inserted into the retainer. If equipped with tab ‘washer, bend the two restraining tabs out so the retainer can be removed. ‘The retainer is now screwed out ofthe output shaft. The two-piece retainer used on the $92 steering gear is removed with a standard socket arangement. ($-23 - $-24) sat S28 Page 26 SHEPPARD POWER STEERING SERVICE MANUAL ‘Separate the mounting bracket from the steering gear, if used Make reference marks on the bearing cap; cylinder head and hous- ing so that the steering gear ean be reassembled in the same ‘configuration Note: The cylinder head and bearing cap will ft ether end of the housing. Remove the relief valve plungers from the cylinder head and the bearing cap. This will protect them from damage during repairs. (Clean che exposed portion of the output shaft to prevent damaging the bearing Page 27 SHEPPARD POWER STEERING SERVICE MANUAL Remove the eight bolts altaching the pinion gear cover to the housing. Using 2 soft hammer, tap on the end of the output shaft 0 loosen the cover. Carefully side the output ‘shaft, pinion gear, and cover through the housing. Pull the output shaft out of the cover. Remove and discard the cover "O"-ring seal Note: Early 592 series 5 steering gears used loose needle roller bearings in the cover and housing to support the output shaft. On disassembly the needle rollers forthe two bearings must be Kept separate. See Series $ variation. ‘Remove the cylinder head and discard the seal sing. Page 28 SHEPPARD POWER STEERING SERVICE MANUAL. Remove the bolts from the bearing cap, and tum the actuating shaft to free the beating cap from the piston and housing. 8st Suppor the besring cap and turn the actuating shaft uni itis free of the piston, Remove and discard the seal ring, Carefully slide the piston assembly from the bore of the housing. Note: Series 6 gears are equipped with piston rings. Care must be taken not to damage piston rings when removing the piston from the housing, ‘The steering gear has now been disassembled into subassemblies which can be further disassembled and repaired as required. Page 29 SHEPPARD POWER STEERING SERVICE MANUAL CLEANING & INSPECTION (Cleaning Cleanliness i of utmost importance. Dirt and foreign material introduced into the steering system during repair operations can cause {damages and steering malfunctions ata later date. Due to the close tolerances between mating pats itis adviseble to have all pats atthe same temperature for reassembly, (Clean machined paris individually to avoid damage due ro “bumping together. Use clean solvent to wash pars. Dry parts with compressed tis, Nicks or burrs must be removed with 2 fine hand stone before assembly. Use only clean motor oil to coat parts to ease assembly. AIL “O"-rings, seals and gaskets should be replaced as a part of any repair All hoses, nes and the reservoir and filter should be cleaned before reinstalling repaired steering gear or after pump replacement Inspection ‘A careful visual inspection of all steering gear parts must be made. Worn parts as well as any parts that show signs of stress or fatigue must be replaced, ‘Caution: Stering gears that have been accident damaged should be considered suspect. Impact loads transmitted through the front axle and steering linkage into the steeing gear can stress pars toa point just short of failure, Further use is unsafe and replacement ofthe steering ‘gear assembly and pitman arm is strongly recommended. Distorted pitman arms, broken or beat reversing springs, twisted output shafts, broken or cracked rack and pinion gear teeth are some signs of impact damages. Broken or damaged mounting brackets should not bere placed without further investigation Steering Gear parts inspection may reveal problems in other areas of the steering system. To avoid repeat problems each clue gained from parts inspection should be followed to conclusion. Listed below are the more common observations you may make during steering gear inspection and their possible cause. This information should be considered carefully when repairing low mileage vehicles. Remember its ‘more important to repeir the eause than to repair the results Pars discolored (Bue) 1. Operating temperatures coo high | Actuaing stat bearing retaining 1. tmpact or accident damaged 2, Flow rate excessive aut sipped 2. Ain system 5: System backpressure too high 4. Stectng column binding Housing or piston scoring Foreign materia enry 5. Actuating vale blocked (Also se fellowing NOTE) Severe overloading 6. Hyatt sappy pump Tncorect lubricant used ma temperate (over Incorrect lbricat sed [Erosive tomperaure Broaze bushing wear 1 2 3. Overloading 4 Pump damaged Air in system i Contaminated oit Roller Bearings 1. Operating pressure too high ‘Pined rough) 2 Roveign material in system ‘Actusting shal and setting 1. Incorrect lubricant weed (Bearing cage broken) 3, Excessive overloading valve some tread wear 2, Overoad 3. Insufficient operating pressure Roller Boaings| 1. Impact damages 4, Inefficient oll ow Nesdlesflatoned 5. Continued operation 2 high ‘Our shaft rinetod femerature or dented Token oF bent reversing spring 1 Accident damaged Piston ngs ewt, 1 Incorrect instalation 2 Aria system Pinched, sheered or wom 2, Incomest disassembly 3 Foreign material entry Broken housing 1 Accident damaged 2. Unconsolled operating pressure Note on scoring Minor scoring and scuffing ofthe piston and housing ofthe steering gear should not be cause for alarm. During operation at relatively high pressures and flow rates this minor scoring will not affect the safety or operation of the steering gear. Minor searing should be polished with a fine hand stone or crocus cloth to allow free movement of mating parts. The cylinder bore should not be honed or bored ‘out as this will increase leakage. Page 30 ‘SHEPPARD POWER STEERING SERVICE MANUAL $98 $39 REPAIR — SHORT SERIES PISTONS ‘To remove the control valve from the piston, the piston plug must firstbe removed, The plugs locked to the piston with a4 inch soft pin. Use @ Ys inch drill to drill out the pin. See variation on early ‘production gears and 372 and 382 step-bore steering gears. Cautions The top adjusting nut which is exposed should never be removed or the reference to the valve center is lost. Use a spanner wrench to remove the piston plug from the piston. (Note: The spanner wrench shown here can be fabricated using @ piece of fat stock with two cap screws bolted in place with the proper spacing to ft the piston plug, ‘The seals on the piston plug can be removed ancl discarded if replacement is required. Page 31 SHEPPARD POWER STEERING SERVICE MANUAL Mask the top adjustment mat and piston so thatthe nut an be rein stalled in its original position. L oe Caution: Misedjustment of the top adjustment nut could cause oe , oid ‘4 wg ba ieee a iorcpamc eee sw perpen pinion Carefully slide the control valve and reversing springs out of the sas ee ‘The valve positioning pin can now be removed from the piston. 845 Remove and discard the seal onthe valve positioning pin. Remove a the remaining two reversing springs. Page 32 SHEPPARD POWER STEERING SERVICE MANUAL S48 Toe By, nur porrom Pus ‘A.3/16 inch allen wrench is used to remove the retief valve seats ‘There is a slight spring tension on the relief ball valves. ‘Caution: Handle carefully to avoid loss or personal injury ‘The relief passage is drilled through the piston from end-to-end. ‘There is ball valve and a valve seat at each end. The ball valves, are held against their seats by a spiral spring, ‘The components of the piston and actuating valve assembly can now be cleened and inspected. The reversing springs and the relief system parts are the oaly replaceable pars inthe piston. The reversing springs should be flat. Bent or dished springs are an indication of severe impact damages and all components of the steeting gear should be inspected for damages. Page 33 SHEPPARD POWER STEERING SERVICE MANUAL Carefully reassemble the piston, Place two reversing springs on the cenier ofthe adjusting nut in the piston. Put a new O-ring seal on the valve positioning pin and screw the pin into the piston until the top of the pin is below the surface of the piston Reinstall the actuating valve in the piston withthe long locating slot in line with the valve positioning pin. Turn the valve position ing pin uni it lines up withthe slotof the valve and the valve slides, into the reversing springs Note: Some 392 Short Series 3 and 4 pistons also wse a tapered valve positioning pin, which is adjustable. These pistons can be identified by the piston plug which uses seal rings. These pistons will also have a control valve with a maximum inch and tree quarter diameter (for adjustment, see variation tapered valve posl- tioning pin, next page). S49 Place the two reversing springs on the nose of the valve. Serew the adjusting nut into te piston until the nut contacts the eversing springs and the valve has no end play. Now turn the adjusting rut 10 ine up your reference marks and the locking pin will enter the original pin holes. If the lock pin will not enter the original holes a second hole is provided and the adjusting mut can be drilled and the pin installed in this position. The tip of the pin must be below the surface of the piston 851 Install a new O-Ring expander and a new square ring seal on the piston plug and install the plugin te piston. Tighten plug securely Dill and pin the plug to the piston. Tae tip ofthe pin must be below the surface of the piston. Reinstall the relief valve seats, bells and springs. ‘SHEPPARD POWER STEERING SERVICE MANUAL VARIATION — TAPERED VALVE POSITIONING PIN USED ON: LATE MODEL SHORT SERIES 3 & 4 AND ALL SHORT SERIES 5 & 6 ‘Tapered Valve Positioning Pin Identification All series 5 and series 6 gears are equipped with tapered valve positioning pins. Late model series 3 and 4 pistons also use @ lapered valve positioning pin, which is adjustable. These pistons ‘canbe identified by the piston plug which uses seal rings (see photo 8-52 page 34). ‘The valve positioning pin which locates and guides the actuating valve in the piston of the Series $ gear is tapered. This tapered valve positioning pin must be adjusted when the piston is reas- sembled. Install a new O-Ring Sea! on the valve positioning pin and serew it nto the piston until i is lush with the surface of the piston. Make reference marks with a pencil on the piston and the pin and then install the actuating valve in the piston, ining up the long guide slot in the valve with the guide pin. When the valve position- ing pin has entered the valve and the valve has botiomed, check the valve for radial movement and froodom of movement over the valve positioning pin. ‘The valve positioning pin is adjusted 1/4 turn ata time’ until the valve has no radial movement and slides smoothly over the valve positioning pin. Fach time the valve positioning pin is adjusted the actuating valve will have to be pulled out of the piston far enough te disengage the valve positioning pin. When the valve positioning pin is properly adjusted complete assembly of the piston as pre- viously detailed for Series 5 Steering Gears Page 35, SHEPPARD POWER STEERING SERVICE MANUAL SERIES 6 — PISTON SEALS Seties 6 pistons use teflon rings with backup o-ing seal. In ad dition, a slipper seal and backup o-ring is used on the pressure supply orifice area, For servicing, remove the used teflon seals and backup o-rings, slipper seal and backup o-ring and replace with new seals and backup o-rings 856 ‘S-58 install backup o-rings on piston ends and slipper seal area. ‘Carefully place teflon seals and slipper sel in position on cylinder. ‘8-59 using «ring compressor, carefully install the piston inthe gear housing, ‘Caution: You will have to carefully work the piston ring past the pinion gear opening in the cylinder bore. See $-60. While msin- taining pressure on the end of the piston, use the blunt end of a ‘wooden stick to press the piston seal into the ring groove. As the piston ring is compressed into the ring groove the piston wil slide further into the bore until the piston ring has passed the pinion gear b rmosen owt. il -ornng sureen sean) “OT AING Note: Due to the nature of the seal material it wll stretch as it is A fikted tothe ring groove. If you let the piston set with te eal rings 7 in place they will contract and it will become easier to install tin the piston bore. When installing the piston inthe housing bore, use the end of the housing with PA. east onto the housing. See $-60. ‘This end only contains a lead-in chamfer to help guide the piston ‘and teflon piston ring into the housing bore. PA SIDE S60 Page 36 SHEPPARD POWER STI EERING SERVICE MANUAL SERIES 6 — OPTIONAL INTEGRAL ‘An optional, integral, pressure relief valve is offered with the ‘Sheppard Seties 6 Steering Gear. This valve is mounted internally in the piston and limits the maximum operating pressure in the steering system. In most cases the hydraulic supply pump will have ‘maximum relief pressure setting several hundred pounds higher than the rolief valve integral with the steering gear. ‘Therefore, when maximum relief pressures are reached in the steering system the excess pressure is relieved at the stering gear and the supply pump is nat subjected to high temperatures caused by normal pressure reli and recirculation within the supply pump. ‘The optional pressure relief valve offered withthe Sheppard Series 6 Steering Gear isan integral pat of the piston. When oil pressure ‘exceeds the maximum relief pressure setting of the pilot operated reli valve the valve opens and excess pressure is bed off into the oil return circuit through the pinion gear bore of the stering gear. PISTON RELIEF VALVE ‘The valve is disassembled for cleaning and inspection by removing the valve end plug and withdrawing the relief valve and com- ensating spring. Toremove the end plug it will be necessary ode, ‘out the locking pin. When the pressure relief valvo is reassembled in the piston, realign end plug with the locking pin hoe after inserting the relief valve and ‘compensating spring into the relief valve bore. Install anew locking, pin fo re-secure the end plug ‘Test procedures forthe integral reli valve ae listed on page SS. RELIEF VALVE INSTALLATION IN PISTION ISTON {ELIEF VALVE ASS'Y RING. aN LOCKING PIN ELIEF LA ‘SECTION VIEW A-A ENO VIEW Relief Kits at Right Include: 1 — Relief Valve Ass'y 1 Spring. 1-ORing 1 = Locking Pin L=Plug ve Replacement Kits Pressure Setting PartNo. [PSE] Bar r7s0911K | 1300 | 103 yreep12K | 1739 | 120 yrso0913K | 180 | 127 rreoogi4k | ise | 130 v7600915K } 2000 | 138 rieoopt6x | 2100 | 145 Page 37 SHEPPARD POWER STEERING SERVICE MANUAL VARIATIONS — EARLY PRODUCTION PISTONS Note: Variations Very early production steering gears may be fitted with piston rings. They can be removed and discarded as they are no longer required, The 372/382 series steering gears with the step-bore hhousing and piston flange will continue to usc the piston ring The piston bottom plug should not be removed except in cases of severe oil contamination, and for clesning. On reinstallation the plug must be pinned. Pipe sealer should be used sparingly on the threads of the plug. ‘Mark the tap adjustment nut and piston so that the nut can be rein- stalled in its original position. Caution: Misadjustment of the top adjustment aut could cause erratic steering, Carefully remove the pin locking the adjustment nut tothe piston assembly. Page 38 SHEPPARD POWER STEERING SERVICE MANUAL Using & spanner wrench remove the top adjusting nut from the piston. ‘Note: The botiom adjustment nut inside piston should never be removed. 8465 Remove the top reversing spring from the nose of the actuating valve, ing valve fram the piston. Do not force the valve from the piston bore. The actuating valve and piston are serviced ‘only as an assembly due to the eritical tolerances in this area. Remove the actuating valve positioning pin from the piston, ‘Note: The positioning pin on Ister production steering gears will have an “O”-ring oil seal. $08 Page 39 SHEPPARD POWER STEERING SERVICE MANUAL ‘Te reversing springs are the only serviceable pars in the pion ra E assembly Use an allen wrench to remove the relief ball seats, relief balls and spring ‘Caution: The balls are under slight spring pressure, Handle care- fally t avoid loss or personal injury. rc @ > EI MAMOAMMOTNTMNAARONN $70 REASSEMBLY — EARLY PRODUCTION PISTONS Position the relief valve spring and one relief valve ball into the valve bore. Then, using a 3/16" allen wrench, install one of the valve seats. The valve seats must be tight and flush with or slightly below tie end surface of the piston Install the second relief valve ball seat in the same manner Postion one of the reversing springs in bottom of valve bore. Be sure spring is centered, The end of the valve must enter the inside icmeter of the spring. Install the valve positioning pin inthe piston. Turn pin inward with 2 screwdriver until it is below the outside surface of the piston. ‘The flats must enter into the piston 1/4” to engage the mating slot in the valve Carefully slide the actuating valve into the piston so thatthe stot ‘on the end of the valve is positioned over the pin. Position the remaining reversing spring on shoulder of the valve end. Reinstall valve adjustment nut, turning it clockwise into the piston ‘uni itis against the spring. Align the reference marks on the nut and piston. Then, lock nut in place by installing the locking pin. Bo sure pin is below the outside edge of piston Page 40 SHEPPARD POWER STEERING SERVICE MANUAL PISTON VARIATION — 372-382 SERIES — STEP-BORE ‘The step-bore 372-382 pistons are disessembled the same as the ssandard piston, except the piston ring flange is factory located and installed and must not be removed. $73 ‘The piston ring is replaceable in the caso of wear or breakage. Page 41 SHEPPARD POWER STEERING SERVICE MANUAL REPAIR SHORT SERIES — BEARING CAP ASSEMBLY Separate the actuating shaft from the beating cap. The actuating shaft retainer is pinned to the bearing cap. Use a 5/64 inch drill ‘and drill through the pin, Use a spanner wrench to remove the retainer, ‘You can fabricate your own spanner wrenches as required using discarded retsinors and a piece of stock as a handle and two roll pins. Dril through the retainer and dive the roll pins through the retainer, Weld the stock material 2s a handle tothe retainer. Carefully tep or press the actuating shaft and bear- 879 ing out of the bearing cap. ‘The actuating shaft and bearing are not supplied separately. No attempt should be made to remove the bearing. ‘The bearing cap seals are removed by pressing them toward the inside. Notes The high-pressure cal back up washer will also be displaced with the seals, and should be recovered for reinstallation with new seals, unless the hi-pressaze seal is being replaced with hi-pressure seal kit No. 2370461 (see illustration on following page). Page 42 SHEPPARD POWER STEERING SERVICE MANUAL Ya {paces one ‘ewig se eters dio NOTE: cxdup wer an NOTE Oa irpecue | aioe rom te 0. est Se, Series 3, 4, 5 and early 6 high pressure seal installation A second salt seal and an umbrella syle seal are used on most axle ‘moant steering gears. The illustration above details this seal ar rangement. Seal replacement isthe same as detailed above except the second salt seal is installed in the beating cap. sore boas Late model Series 6 high pressure seal installation Soran Siteote se ae An extended bearing cap which includes a needle bearing supports all extended shaft designs. Notes For seal replacement, remove actuating shaft, use a serew diver to pey out the salt seal. Insert a punch through the needle Dearing bore and tap out the dirt and hispessure seas, Reassembly procedure of actuating shaft and bearing cap seals are as follows: 1. Place the backup washer in the bearing cap with the undercut down as shown (S-80), 2, Takes piece of round stock2" long and turn to 1.615 and smooth one end. Put the piece of round stock in the bearing end against the backup washer, or agains the shoulder area forthe bi-pressure seal ifabackup washer isnotused. Secthe bearing cap ona press and evenly install the dit seal, lip out from the other ené unt it rests agains! the backup washer, or the round stock as shown 80, Everly install the salt sea, lip out, into the bearing cep until ‘lush with top. 3. Tum bearing cap over, when replacing the high pressure seal 2350541 as pictured above with a duplicate seal. Backup washer ‘2261721 must be installed with the undercut down as shown (6-80) ‘When replacing hi-pressure seal 2350541, with hi-pressure seal 2370461, the original backup washer 2261721 must be dis- ‘carded, as the new hi-pressure teflon seal kit 2370461 has the backup washer builtin. Evenly install the hi-pressure oil seal unl i ests against the backup washer, or the shoulder. Lubricate all thrve seals with grease before installing actuating shaft assembly, ‘Caution: Ifthe backup washer is not installed properly, an il, Jeak will occar on the frst application of pressure. sat Page 43 SHEPPARD POWER STEERING SERVICE MANUAL Press the actuating shaft into the bearing cap. Reinstall the bearing fetainer, Tighten retainer securely to keep the bearing ftom having end play. Install a new lock pin, and peen it in place. cut VARIATION — VERY EARLY PRODUCTION — BEARING CAPS Some easly production steering gears used two seals in the bearing ‘cep and the back up washer was machined in the bearing cap housing, Use a screwdriver to pry out the dirt sal ‘With the dirt seal removed, «wo access holes to the high-pressure seal are uncovered. Use a punch to tap the high-pressure seal out of the housing, Care must be taken to avoid damage to the housing (of oil leakage will eoceur, Page 44 SHEPPARD POWER STEERING SERVICE MANUAL REPAIR — SHORT SERIES — OUTPUT ‘The pinion gear is located and held in place on the output shaft With a retaining pin. A roll pin dhrough the pinion gear will keep the retaining pin from backing out of place. To remove the pinion ‘gear, punch out the roll pin and drill out the retaining pin. Press ‘the pinion gear off the output shaft ‘Note: Ifthe retaining pin cannot be drilled out, it can be sheared ‘off with approximately 10 tons of pressure on a press, Dr the pin out of the pinion gear and now drill the remat ‘out of the shaft Caution: Use safety precautions when shearing the pin under pressure. ‘To reassemble the pinion gear to the output shaft, align the timing arrows on the output shaft to the arrow on the pinion gear. Press ‘he gear on tothe shaft splines uatil the locating pin can be driven through the gear and into the locating hole in the shaft, Install the roll pin through the gear. ‘To provide 100 degrees of pitman arm travel some series 5 & series 6 steering gears use a one piece forged output shaft and pinion gear assembly, Service of this assembly is by replacement only. ‘The 372/382 series output shaft and pinion gear are diferent in appearance but are serviced in the same manner as the high- pressure or short series gears. SHAFT AND PINION VARIATION — OUTPUT SHAFT SERIES 5 & 6 Page 45 SHEPPARD POWER STEERING SERVICE MANUAL VARIATION: LOW PRESSURE SERIES ‘Use am allen wrench to zemove the cap serews, The retaining nut is now removed by turning it counter-clockwise-off the output shaft. Press the gear off the sha “The pinion gear on low pressure steering gears is held vo the out- pt shaft with a retaining nut threaded othe output shaft and locked to the pinion gear with two cap screws. ‘When the pinion gear is reinstalled on the output shaft the dis tance between the end ofthe shaft to the face of the retainer must ‘be adjusted. Place the gear on the shaft splines, aligning the timing ‘marks and thread the retainer onto the shaft against te pinion gear. "The distance between the end of the shaft and the face of the re- tainer should be adjusted by moving the gear on the shaft until the following dimension is obtained: Model 39 — 1%" Model 59. = P%2" Model 491 = 1%2" [Now th retainers backed off until the tiled hoes inthe retainer align wih the tapped hols in the pinion gear. Install end tighten retaining sews drawing the gear tightly against the retainer, It ray be necessary to press the gear onto the shaft or Back agninst the rezine. OUTPUT SHAFT & PINION Page 46 SHEPPARD POWER STEERING SERVICE MANUAL REPAIR — SHORT SERIES — HOUSING ASSEMBLY ‘The bronze bearings are presized and boring or honing are not required. Remove the Quad ring ol seal from the gear housing and discard. ‘Use a drift punch to drive the bronze bearing out of the housing. Alternately tap one side of the bearing and then at an opposite side to keep it moving evenly. ‘Withdraw the bronze bearing from the cover witha suitable bush- ing remover. - (Owatonna Tools puller illustrated Page 47 SHEPPARD POWER STEERING SERVICE MANUAL Page 48 Install new bearings (if removed) in the gear housing and cover, using a press and a straight line pushing action. The bushing is pushed ino the gear housing, so thatthe inside face of bushing is ‘sh with inside face of gear housing Install x new Quad sing in the groove in the gear housing. The quad rng is a “stuff-fit” and at first glance may appear to be too large. Press a new bronze bearing into the pinion cover. ‘The bronze bearing should be recessed % inch below the face of the cover, on all 292, 392 and 492 steering gears. The $92 bearing, is recessed 5/16’. All other bearings are installed flush with the face of the cover. SHEPPARD POWER STEERING SERVICE MANUAL VARIATION — SERIES 5 - se101 OUTPUT SHAFT SEAL REPLACEMENT s-102 Procedure: Remove pitman arin retainer, item 6, and pitman arm, item 5, from sha. Remove socket heed capscrews, item 4, and discard. (S-101) . Remove retainer plate, item 3, clean and save for re-assembly. Remove ol seal, item 2, snd snap ring, item 1, from housing bore and discard. (not applicable to $92) Lubricate the O.D. and LD. of seat assembly, item 7, with chassis lube or equivalent. Wrap the splined end of shaft with ‘greased paper and side the seal into place over the shafi.(S-102) Carefully tap seal assembly into housing bore wnt it is fash with face of housing, Install ecaner plate, item 3, and (4) hex head capscrews, item 8, as shown. Bolt torque to be 10 to 14 fLIbs. (1.40 1,9 KG-M), ‘To facilitate furue service both the retainer plate and hex head ccapscrows can be sprayed with undercoating. Care should be taken to avoid spraying the shaft and housing face on base mount applications. Install pitman arm, item 5, by aligning timing mark on pitman arm with timing mark on shat. Install pitman arm retainer, item 6, by applying lok-cease, never seca or white lead between pitman arm and retainer, in the theads of the shaft, and on the threads ofthe retainer. Pitman arm retainer to be torqued to: 292-392 225 f.bs (31.1 KG-M) 492.592 450 fulbs (62.2 KG-M) SERVICE SEAL REPLACEMENT KITS 29285 & 39285 - 2370481K 449285 ~ 2370491K 59285 ~ 2370501K Page 49 SHEPPARD POWER STEERING SERVICE MANUAL VARIATION — SERIES 5 — HOUSING REPAIR I the needle bearing in the housing is to be replaced, the output shaft seal and snap ring Gf used) must be removed to gain access 10 the bearing. Remove the bearing from the housing by pressing it cut On reassombly, press the bearing into the housing until iti flush with the inside surface of the housing. Note: The $9255 bearing has the snap ring on the bearing. In this case the bearing is pressed into the housing until the snap ring contacts the housing ‘The needle bearing in the pinion cover is removed using a bushing removal fool similar tothe Owatonna puller iustated, (Note: The bearing should not be removed unless itis going to be replaced, ‘A new bearing is pressed into place flush with the face ofthe bearing bore and against the spacer in the bore of the pinion housing, Note: Some 592 series 5 steering gears use @ double row needle beating where the needle rollers are loose. During service, cae must be teken to ensure that tho needle rollers are installed in the bearing housing which they came out of. Use chassis lube to hold the needle rollers in the bearing races curing reassembly. Note: The 59255 bearing has the snap ring on the bearing, In this ‘ase the bearing is pressed into the cover until he snap ring contacts the cover. Page 50 SHEPPARD POWER STEERING SERVICE MANUAL SERIES 6 —- COVER & HOUSING REPAIR SS = Li ss xy / Procedures for Oil Seal and Bearing Replacement 1. Remove 8 housing bolts and housing cover. 2, Remove sector shaft assembly. 3. Remove the bearings from the housing and housing cover, ‘The needle bearings are removed using a bushing removal tool, similar to the Owatonna puller pictured in ($-105). Notes The bearings do not have to be removed to replace the oi, seals, 44, Remove and replace sector shat oll seals from the housing, and housing coverif applicable, (Note: An additional ol seals used in the housing cover if the goar is used in a hydraulic brake booster system.) Page SI SHEPPARD POWER STEERING SERVICE MANUAL REASSEMBLY ‘Typical overhaul seal kit SERIES 6 — HOUSING REPAIR Procedures for Oil Seal and Bearing Installation 1, Place the new sector shaft oil seals in the housing and housing ‘cover if epplicable. (See illustration on previous page) 2, Press bearing into position in the housing and housing cover. “The bearing should bottom out against a shoulder so the bearing {s flush withthe inside surface of the housing or housing cover. 3. Toproiect the ol seal, cover the splines on the sector shaft with S108 wax paper and lubricate the paper and sector shaft with motor oil. (similar 0 S-102) 4. Align the timing smack on the piston and pinion gear. (See instructions on following page.) 5. Caefully install the sector shaft in the housing, Take special ‘are not to damage the ol seals or leave dirt or contamination in the gear 6. Aliga timing mark on piston rack with timing marks on sector shaft. (See photo $-110). Caution: I the rack is not properly timed tothe pinion gear ofthe forged one-piece sheft and gear assembly it is possible forthe gears to disengage in serviee. 7. Proceed with final assembly per instructions on following pages. Page 52 ‘SHEPPARD POWER STEERING SERVICE MANUAL Install cylinder head with new gasket or seal. Align reference marks and tighten bolts to specified torque. Using anew gasket orseal onthe bearing cap, thread actuating shaft into the valve. Line up punch marks on gear housing and bearing cap. Tarn shaft until cap comes into place on the end of cylinder, ‘Check plunger hale alignment with valve seat inthe piston. Tighten ‘bots to specified torque. Several steering. gear models use square ring seals in place of {gaskets on the cylinder head and bearing cap. Position a new “Oring seal on housing cover. Install cover assembly. Itmay be necessary touse soft hammer to tap the cover in place, Install the bolts and torque to proper specifications. TORQUE SPECIFICATIONS APPLICATION SWE FTLBS. (CYLINDER HEAD AND BEARING CAP /I6-25NF_ 2030 CYLINDER HEAD AND BEARING CAP _WK—25NE 35.5, STEERING GEAR COVER (MOUNTED) 7/16~20NF_ 5545, STEERING GEAR COVER (MOUNTED) © V/2~20NF_ 8595, STEERING GEAR COVER (MOUNTED) 9116 18NF_ 120-120 ‘STEERING GEAR COVER (MOUNTED) 5/8 ISNF-_ 170.180 STEERING GEAR COVER (MOUNTED) SB— LINC 1504160 ‘STEERING GEAR COVER (STANDARD) 7/16 20NF_ 35.40 ‘STEERING GEAR COVER (STANDARD) S055 STEERING GEAR COVER (STANDARD) 70 ‘STEERING GEAR COVER (STANDARD) 100-110 ‘STEERING GEAR COVER (STANDARD) 30.100 MITER ACT. SHAFT LOCK NUP 4555 is ‘The relief valve plungers may now be installed, using new “0""-tings. Coat "O"-ring with lubricant before installation, Turn them approximately six tums. Final adjustment of the plungers are made when the steering gear is installed on the vehicle. 8413 Note: Variation Later production steeing gears may have slotted and recessed relief plunger. The later style plungers are removed or adjusted with a straight bladed screwdriver. ‘These phingers ean be turned out until they are flush with the plungerboss, Turing them out beyond this point could cause anol leak. Reinstall the bracket on the steering gear end torque the bolts to specification Page 33, SHEPPARD POWER STEERING SERVICE MANUAL OPTIONAL — INTEGRAL RELIEF Note Series 5 extra pressure rl pete VALVE SERVICING Am options, integral, pressre reli valve is offered. with the ‘Sheppard Set 5 Stsrng Geer. This valve mounted extraly ‘on the Steering Gear and limits the maximum operating pressure in the steering system. In most cases the hydraulic supply pump ss wl have a maximam zlist pressure sting several hundred pounds higher than the reli valve integral with the stering gar. Therefore, when macimam cele presses are reached inthe sterng sytem the excess press is relleved at the seeing fear andthe supply pump 8 ot sibjectd o high texpertues Caused by normal presse rie’ and recirculation within the supply pump, ‘The optional pressure relief valve offered with the Sheppard Series 5 Steering Gear bolts externally to the steering gear housing and ‘connects the high-pressure supply circuit to the low pressure pinion gear area of the steering gear. When oil pressure exceeds the maximum relief pressure setting of the plot operated relief valve the valve opens and excess pressure is bled off into the oil return

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