Contents Section: Manual & Power Steering All sections

Steering System Dodge Ram Wagon B3500

Manual & Power Steering 14 illustrations ~4011 words

DESCRIPTION & OPERATION

The recirculating ball power steering system consists of steering gear, steering linkage, pressure and return fluid hoses and fittings, and a hydraulic steering pump with fluid reservoir.

The steering gear is a power assisted recirculating-ball type that acts as a rolling thread between worm shaft and rack piston. (Scheme 1) When worm shaft is turned, the rack piston moves an d piston teeth mesh with sector shaft teeth, turning pitman arm, which turns steering linkage.

The steering linkage consists of pitman arm, idler arm(s), tie rods and center link.

The power steering pump is a constant flow rate and displacement, vane-type pump. Pump is connected to steering gear by pressure and return hoses. On gasoline models, pump shaft has pressed on belt-driven pulley.

Scheme 1

Scheme 1: DESCRIPTION & OPERATION

TESTING

Note. Before testing, check fluid level, belt tension, pump pulley, tire pressure and engine idle speed.

HYDRAULIC SYSTEM PRESSURE TEST

Note. Replacement fittings are required on Pressure Test Gauge(C-3309E) for adapting to "O" ring type hose tube ends.

Scheme 2

Scheme 2: Idle Pressure Test
  1. Remove high pressure hose at steering pump and connect a spare hose to pump fitting. Connect opposite end of spare hose to Pressure Test Gauge (C-3309E). Connect pressure hose from valve side of steering gear to valve side of gauge. Valve must be installed on outlet side of gauge. (Scheme 2)
  2. Fully open shutoff valve on test gauge. With a thermometer in fluid reservoir, start engine and warm fluid to 150-170°F (66-77°C). Turning wheels from stop-to-stop will aid in warming fluid. DO NOT hold wheels against stop.
  3. With engine at idle and gauge valve open, check initial pressure. See «POWER STEERING PUMP PRESSURE TEST SPECIFICATIONS»(/dodge/ram-wagon-b3500/1991-2000/remont/manual-power-steering/#steering-system) table. If pressure is greater than 125 psi (8.8 kg/cm 2 ), check for restricted hoses or crimped lines.
ApplicationPsi (kg/cm 2 )
Idle Pressure50-80 (3.5-5.6)
Relief Pressure1350-1450 (94.9-101.9)

POWER STEERING PUMP PRESSURE TEST SPECIFICATIONS

CAUTIONDO NOT leave shutoff valve closed more than 5 seconds, or pump damage could result.

Relief Pressure Test

  1. Close gauge shutoff valve completely 3 times. Record highest pressure attained each time. All 3 readings must be greater than specifications and within 50 psi (3.5 kg/cm 2 ) of each other. See «POWER STEERING PUMP PRESSURE TEST SPECIFICATIONS»(/dodge/ram-wagon-b3500/1991-2000/remont/manual-power-steering/#steering-system) table. If pressures are not as specified, replace pump. See «POWER STEERING PUMP»(/dodge/ram-wagon-b3500/1991-2000/remont/manual-power-steering/#steering-system__power-steering-pump) under REMOVAL & INSTALLATION. CAUTION: DO NOT hold steering wheel against stops more than 4 seconds, or pump damage may result.
  2. Open test valve and turn steering wheel to left and right stops. Record highest pressure attained at each stop. If output pressures are not equal against each stop, gear is leaking internally and must be repaired or replaced. See «STEERING GEAR»(/dodge/ram-wagon-b3500/1991-2000/remont/manual-power-steering/#steering-system) procedure under REMOVAL & INSTALLATION and/or OVERHAUL. Shut off engine, remove test gauge, and connect pressure hose.

CAPACITY

ModelsPts. (L)
Ram Van/Wagon2.7 (1.3)

CAPACITY

FLUID TYPE

Use Mopar Power Steering Fluid (4318055).

For additional information, refer to POWER STEERING FLUID USAGE .

CAUTIONDO NOT use Automatic Transmission Fluid (ATF).

FLUID LEVEL CHECK

Check fluid level with engine cold and not running. Remove fluid level dipstick on pump reservoir. Dipstick should indicate FULL COLD with fluid temperature of 70-80°F (21-27°C). If needed, add fluid through dipstick opening, and recheck. DO NOT overfill.

HYDRAULIC SYSTEM BLEEDING

Fill power steering pump reservoir to specified level. Start engine and slowly turn steering wheel to left and right but DO NOT contact steering stops in either direction. Stop engine. Inspect reservoir fluid level and add fluid if necessary. Bleeding process may have to be repeated several times to completely purge all air from system.

STEERING PUMP BELT

Vehicles are equipped with dynamic tensioner. No adjustment is required.

STEERING PUMP PULLEY

After pulley installation, run engine until warm. See PUMP PULLEY under REMOVAL & INSTALLATION. If belt chirp exists, move pulley outward approximately .020" (0.5 mm). If noise increases, press pulley inward .040" (1.0 mm). Ensure pulley does not contact mounting bolts.

THRUST BEARING PRELOAD

Note. Manufacturer recommends removing steering gear from vehicle before performing any adjustments.

Scheme 3

Scheme 3: THRUST BEARING PRELOAD
  1. Remove steering gear from vehicle. See «STEERING GEAR»(/dodge/ram-wagon-b3500/1991-2000/remont/manual-power-steering/#steering-system) under REMOVAL & INSTALLATION. Ensure steering gear is empty of hydraulic fluid. Rotate steering from stop-to-stop several times to drain fluid. Loosen lock nut on adjuster plug. (Scheme 3) Using spanner wrench, rotate adjuster plug clockwise until plug is seated in housing. Torque will be approximately 20 ft. lbs. (27 N.m).
  2. Place reference mark on steering gear housing adjacent to one hole in adjuster plug. Measure counterclockwise about 1/2" (13 mm) from reference mark and place a second reference mark on steering gear housing.
  3. Rotate adjuster plug counterclockwise until hole in adjuster plug aligns with second mark on steering gear housing. Tighten lock nut on adjuster plug to 80 ft. lbs. (108 N.m). Ensure adjuster plug DOES NOT move while tightening lock nut.

OVER-CENTER PRELOAD

CAUTIONThrust bearing preload MUST be adjusted before adjusting over-center preload.

Scheme 4

Scheme 4
  1. Loosen lock nut on sector shaft adjuster screw. (Scheme 4) Rotate stub shaft and count turns required to go from stop-to-stop. Turn stub shaft back 1/2 number of turns to center steering gear.
  2. Rotate sector shaft adjuster screw counterclockwise until fully extended, then turn clockwise one full turn. Attach INCH-lb. torque wrench to end of stub shaft. Position torque wrench handle in a vertical position. Rotate stub shaft 45 degrees from vertical position in each direction, and record highest reading. (Scheme 4)
  3. Turn adjuster in until torque required to turn stub shaft is 6-10 INCH lbs. (0.7-1.1 N.m) more than reading in step 2). Hold adjuster screw, and tighten lock nut to 36 ft. lbs. (49 N.m).

REMOVAL & INSTALLATION

CAUTIONWhen battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See the COMPUTER RELEARN PROCEDURES article in the GENERAL INFORMATION section before disconnecting battery.

POWER STEERING PUMP (GASOLINE)

WARNINGDO NOT attempt to remove power steering pump without removing power steering pump belt. Personal injury or pulley damage could result.

Removal

  1. Disconnect and isolate negative battery cable. To remove serpentine belt, rotate tensioner clockwise and hold in place, slide belt from tensioner pulley. Place drain pan under pump. Disconnect and cap hoses.
  2. Remove bracket-to-engine block bolts. Remove pump, pulley and mounting bracket as an assembly. To allow access to pump screws, remove pump pulley. See «PUMP PULLEY»(/dodge/ram-wagon-b3500/1991-2000/remont/manual-power-steering/#steering-system__pump-pulley) under REMOVAL & INSTALLATION. Remove bracket-to-pump screws.

Installation

To install pump, reverse removal procedure. Fill and bleed system. See HYDRAULIC SYSTEM BLEEDING under LUBRICATION.

PUMP PULLEY

CAUTIONExamine exposed end of rotor drive shaft before removal. If it is corroded, clean surface with crocus cloth to prevent damage to shaft bushing during removal.

Removal & Installation (Gasoline)

Remove power steering pump from vehicle if necessary. See POWER STEERING PUMP under REMOVAL & INSTALLATION. Using Puller (C-4068) and Puller Adapter (C-4068-1), remove pump pulley. (Scheme 5) Replace pulley if bent, cracked or loose. Using Installer (C-4063), press pulley until flush with shaft end. If belt chirp exists after starting engine, See STEERING PUMP PULLEY under ADJUSTMENTS.

Scheme 5

Scheme 5: Removal & Installation (Gasoline)
  1. Remove power steering pump from vehicle if necessary. See «POWER STEERING PUMP»(/dodge/ram-wagon-b3500/1991-2000/remont/manual-power-steering/#steering-system__power-steering-pump) under REMOVAL & INSTALLATION. Remove filler cap and drain oil from reservoir before removing parts. Remove 2 studs and fitting from back of pump. (Scheme 6)
  2. Rock reservoir by hand or tap with soft-faced mallet to remove it. Remove "O" ring seals from housing and reservoir. Remove flow control valve and spring from rear of pump housing. (Scheme 7) Clean all parts.

Note. If expansion plug is deformed or dislodged, DO NOT remove Replace pump housing.

To install, reverse removal procedure. Use NEW "O" ring and seals. Install flow control valve. Tighten flow control valve fitting to 55 ft. lbs. (75 N.m). Apply power steering fluid to new seals. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS . Add power steering fluid. DO NOT use ATF. Bleed system. See HYDRAULIC SYSTEM BLEEDING under LUBRICATION.

Scheme 6

Scheme 6: Installation

Scheme 7

Scheme 7
  1. Place wheels in straight-ahead position. Place drain pan under steering gear assembly. Disconnect and cap pressure and return hoses from steering gear. Disconnect steering column shaft coupling from steering gear stub shaft.
  2. Raise and support vehicle. Disconnect steering linkage (center link) from pitman arm. (Scheme 8) Disconnect stabilizer bar (i f necessary). Place reference mark on pitman arm and sector shaft. Remove nut and pitman arm from sector shaft. Remove steering gear-to-frame bolts. Remove steering gear.
  1. Install steering gear with bolts finger tight. Center steering gear and align stub shaft with steering column. Install steering column shaft coupling bolt and tighten to specification. See «TORQUE SPECIFICATIONS»(/dodge/ram-wagon-b3500/1991-2000/remont/manual-power-steering/#steering-system__torque-specifications) . CAUTION: Stake pitman arm nut against pitman arm to ensure proper retention.
  2. Reposition steering gear to eliminate binding and tighten bolts to specification. Install pitman arm on sector shaft with reference marks aligned. Install lock washer and nut. Tighten nut to specification.
  3. To install remaining components, reverse procedure. Fill pump reservoir. Bleed air from system. See «HYDRAULIC SYSTEM BLEEDING»(/dodge/ram-wagon-b3500/1991-2000/remont/manual-power-steering/#steering-system__hydraulic-system-bleeding) under LUBRICATION.
  1. Raise and support vehicle. Place wheels in straight-ahead position. Disconnect steering linkage (center link) from pitman arm. Disconnect stabilizer bar (if necessary).
  2. Place reference mark on pitman arm and sector shaft. Remove nut and pitman arm from sector shaft. Place drain pan under steering gear. Remove retaining ring and steel washer. (Scheme 1) CAUTION: DO NOT hold steering wheel in left-turn position for more than 2 seconds.
  3. Start engine and momentarily hold steering wheel in extreme left-turn position. When pressure develops, this should force upper oil seal, steel washer and lower oil seal from steering gear housing. Stop engine and remove seals.
  1. Ensure seal bore of steering gear is free of burrs and sector shaft is free of pitting or roughness. Lubricate replacement seals and steel washers with power steering fluid.
  2. Wrap sector shaft with plastic tape or .005" (.13 mm) thick shim stock. Install upper oil seal (single lip seal) and steel washer first. Oil seal must be installed only deep enough to allow for remaining oil seal, steel washer and retaining ring. CAUTION: DO NOT install upper oil seal against inner bore surface of steering gear housing. Oil seals must be installed so each oil seal is separately seated in shaft bore.
  3. Install lower oil seal (double lip seal) and steel washer. Oil seal must be installed only deep enough to allow for steel washer and retaining ring. Remove tape or shim stock and install retaining ring. CAUTION: Stake pitman arm nut against pitman arm to ensure proper retention.
  4. Install pitman arm on sector shaft with reference marks aligned. Install lock washer and nut. Tighten nut to specification. See «TORQUE SPECIFICATIONS»(/dodge/ram-wagon-b3500/1991-2000/remont/manual-power-steering/#steering-system__torque-specifications) .
  5. To install, remaining components, reverse removal procedure. Fill pump reservoir. Allow engine to idle for at least 3 minutes. DO NOT turn wheels during this time. Rotate wheels both directions and check for leaks. Refill pump reservoir.
  1. Raise and support vehicle. Place wheels in straight-ahead position. Place drain pan under steering gear. Rotate housing end cover retainer ring until one end of ring is under small hole in steering gear housing. (Scheme 1) Insert punch through small hole and depress retainer ring. Remove retainer ring. CAUTION: DO NOT rotate steering wheel any more than necessary, as recirculating balls may fall from rack piston.
  2. Rotate steering wheel to left until rack piston forces housing end cover from steering gear housing. Turn steering wheel back to center position. Remove housing end cover and "O" ring.

Lubricate "O" ring with power steering fluid and install on housing end cover. Install housing end cover and retainer ring. Fill pump reservoir. Allow engine to idle for at least 3 minutes. DO NOT turn wheels during this time. Rotate wheels both directions and check for leaks. Refill pump reservoir.

Separate tie rods, idler arm and steering from center link. Remove center link. To install, reverse removal procedure. Tighten nuts to specification.

Scheme 8

Scheme 8: Removal & Installation

Remove cotter pin and nut from idler arm. Separate idler arm from center link. Remove idler arm bolt(s). Remove idler arm. To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Install new cotter pin.

  1. Remove cotter pin and nut at pitman arm-to-center link. Separate pitman arm from center link. Mark location of pitman arm on steering gear shaft. Remove pitman arm-to-steering gear shaft nut. Separate pitman arm from steering gear. CAUTION: Stake pitman arm nut against steering gear shaft to ensure proper retention.
  2. To install, reverse removal procedure. Ensure reference marks are aligned. Tighten bolts and nuts to specification. Install NEW cotter pin.

Remove cotter pin and nut from tie rod end. Using Tie Rod End Puller (C-3894-A), remove tie rod end from steering knuckle or center link. Loosen lock nut or clamp bolt. Remove tie rod end. Note number of turns required for removal.

Note. Use Tie Rod End Puller (C-3894-A) to prevent tie rod end seal damage.

  1. To install, reverse removal procedure. Ensure tie rod end is installed at same location. Position clamp sleeve with bolt located on bottom. Clamp opening should be aligned with slot in sleeve.
  2. Tighten the tie rod end nut to specification. Install NEW cotter pin. Check and adjust toe-in. See the appropriate «WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES»(/dodge/ram-wagon-b3500/1991-2000/remont/wheel-alignment/#wheel-alignment-specifications-procedures) article in the WHEEL ALIGNMENT section. Tighten clamp bolt. See «TORQUE SPECIFICATIONS»(/dodge/ram-wagon-b3500/1991-2000/remont/manual-power-steering/#steering-system__torque-specifications) .

POWER STEERING PUMP

Only fluid reservoirs, caps, pulleys, "O" rings, seals and flow control valve are replaceable on Saginaw pumps. (Scheme 6)and (Scheme 7). Internal components are non-serviceable. If internal components fail, replace pump. Replace reservoir, or "O" ring and seals if damaged. See appropriate component under REMOVAL & INSTALLATION.

Note. If expansion plug is deformed or dislodged, DO NOT remove it. Replace pump housing.

Disassembly

  1. Remove steering gear from vehicle. See «STEERING GEAR»(/dodge/ram-wagon-b3500/1991-2000/remont/manual-power-steering/#steering-system) under REMOVAL & INSTALLATION. Clean exterior of steering gear, and clamp it in a soft-jawed vise so sector shaft is pointing downward. Rotate housing end cover retainer ring until one end of plug is over hole in steering gear housing. (Scheme 1) CAUTION: DO NOT rotate stub shaft more than necessary, or recirculating balls may fall from rack piston.
  2. Force end of retainer ring from groove in steering gear housing and remove ring. Rotate stub shaft counterclockwise to force housing end cover from steering gear housing. Rotate stub shaft clockwise 1/2 turn to move rack piston inward.
  3. Using soft-faced hammer, tap on end plug to unseat it. Remove end plug. Remove lock nut from sector shaft adjuster screw. Remove side cover bolts.
  4. Rotate sector shaft adjuster screw while holding side cover until side cover and gasket can be removed. (Scheme 1) Rotate stub shaft until sector shaft teeth are centered in steering gear housing.
  5. Using a soft-faced hammer, tap end of sector shaft to free it from steering gear housing. Remove sector shaft. Remove retainer adjuster plug lock nut. Using a spanner wrench, remove adjuster plug.
  6. Insert Rack Piston Arbor (C-4175) into end of rack piston assembly until arbor just contacts worm shaft. Rack piston arbor will retain recirculating balls in rack piston. Rotate stub shaft counterclockwise to force rack piston onto rack piston arbor. Remove rack piston and arbor as an assembly.
  7. Remove stub shaft and valve body from steering gear housing by pulling outward on stub shaft splined end. Remove worm shaft, lower thrust bearing and bearing races from steering gear housing.

Cleaning

Clean all internal parts in solvent and dry with compressed air. Avoid wiping valve parts with cloth. Lint may cause binding of mechanism. DO NOT steam clean hydraulic parts. If further disassembly is required, see appropriate sub-assembly heading under OVERHAUL.

Note. Install bearing races so cone (raised area) faces toward steering gear housing. (Scheme 9)

Scheme 9

Scheme 9: Reassembly
  1. Lubricate all parts with power steering fluid before reassembly. Mount steering gear in vise so sector shaft points downward. Install lower thrust bearing and bearing races on worm shaft. (Scheme 9)
  2. Place worm shaft in valve body. Install "O" ring in valve body. Ensure "O" ring is seated against inner edge of stub shaft. Align notch in valve body with drive pin in worm shaft.
  3. Install valve body and worm shaft assembly into steering gear housing. Seat valve body in steering gear housing by pressing on outer diameter surface of valve body with fingertips.
  4. Ensure Teflon rings do not bind in steering gear housing. Valve body is seated when all or most of fluid return port in steering gear housing is fully visible. CAUTION: DO NOT press against stub shaft while seating valve body in steering gear housing. This may cause stub shaft to separate from valve body and allow spool valve "O" ring to fall into fluid passages.
  5. Place Seal Protector (C-4182) over stub shaft. Using NEW "O" ring, install adjuster plug on stub shaft. Using spanner wrench, tighten adjuster plug until it seats against valve body. Approximately 20 ft. lbs. (27 N.m) is required to seat adjuster plug.
  6. Remove seal protector. Loosely install adjuster plug lock nut. Install rack piston (with rack piston arbor to retain recirculating balls) into steering gear housing until worm shaft engages with valve body and stub shaft. Rotate stub shaft clockwise to force rack piston into steering gear housing. Maintain pressure on rack piston arbor until worm shaft is fully engaged.
  7. Rotate stub shaft clockwise to align center groove of rack piston with center of sector shaft bearing bore. Remove arbor. Lubricate rubber portion of sector shaft cover gasket with petroleum jelly.
  8. Install gasket on sector shaft cover. Ensure rubber portion is seated in groove of sector shaft cover. Install sector shaft cover on sector shaft adjuster screw.
  9. Thread sector shaft cover onto adjuster screw until cover contacts sector shaft. Install sector shaft so center gear tooth meshes with center groove in rack piston. Install sector shaft cover bolts and tighten to specification.
  10. Install NEW lock nut half-way on sector shaft adjuster screw. Install end plug in rack piston and tighten to specification. Install housing end cover, end plug and retainer ring.
  11. Ensure end of retainer ring is not aligned with hole in steering gear housing. Lightly tap on housing end cover to ensure retainer ring is fully seated. Adjust worm bearing preload and over-center preload. See THRUST BEARING PRELOAD and OVER-CENTER PRELOAD under «ADJUSTMENTS»(/dodge/ram-wagon-b3500/1991-2000/remont/manual-power-steering/#steering-system).

Scheme 10

Scheme 10: Disassembly
  1. Using a screwdriver, carefully remove and discard retainer. (Scheme 10) Remove spacer, thrust bearing and bearing races. Note direction of bearing race installation for reassembly. Remove and discard "O" ring.
  2. Remove lock nut and retaining ring. Remove dust seal. Pry oil seal from adjuster plug. Inspect needle bearing. Remove needle bearing by pressing bearing out of adjuster plug from spacer end of adjuster plug (if necessary). (Scheme 10)

Inspection

Inspect thrust bearing for cracks. Check rollers for pitting, scoring, or cracking. Check bearing races and spacer for damage. Replace components as necessary.

Reassembly

  1. Lubricate components with power steering fluid. Press needle bearing into adjuster plug with identification number away from adjuster plug until bearing bottoms in bore. Install oil seal with seal lip toward adjuster plug.
  2. Lubricate dust seal with petroleum jelly. Install dust seal with rubber side away from adjuster plug. Install retainer ring. Ensure ring is fully seated. Lubricate "O" ring with petroleum jelly and install on adjuster plug.
  3. Assemble thrust bearing, bearing races, and spacer on adjuster plug. Ensure bearing races are installed in correct location. (Scheme 10) Using a punch, tap NEW retainer into adjuster plug.

Remove ball guide clamp. Place assembly over container to catch recirculating balls. Remove ball guides, worm shaft with arbor and recirculating balls. Ensure 24 recirculating balls are removed. Remove rack piston arbor (if installed). Remove Teflon seal and "O" rings from rack piston.

  1. Clean and dry all parts. Inspect worm shaft and rack piston grooves for scoring. Inspect ball bearings for damage. If any ball bearings are damaged, replace entire set. Check ball guides for pinching of ends.
  2. Inspect lower thrust bearing and races for cracking, scoring, or pitting. Inspect rack piston teeth for chips, cracks, dents or scoring. Replace components as necessary.

Scheme 11

Scheme 11: Reassembly
  1. Lubricate all components with power steering fluid. Install NEW "O" ring onto rack piston. Ensure "O" ring is not twisted. Install NEW Teflon seal over "O" Ring. Insert worm shaft completely into rack piston. NOTE: Ensure a Black ball is installed first, and then a Silver ball is alternately installed in rack piston.
  2. Install recirculating balls in rack piston by alternately installing one Black ball and then one Silver ball. (Scheme 11) Press each ball downward to allow installation of next ball.
  3. A total of 18 balls should be installed in rack piston. Rotate worm shaft counterclockwise as viewed from steering shaft end to install recirculating balls in rack piston.
  4. Apply petroleum jelly to one ball guide and install 6 recirculating balls. Ensure a Black ball is followed by a Silver ball and is in sequence with those installed in rack piston. CAUTION: DO NOT allow rack piston arbor to separate from worm shaft until rack piston is fully installed on worm shaft.
  5. Install remaining ball guide and install both ball guides in rack piston. Install clamp, and tighten bolts to 48 INCH lbs. (5 N.m). Insert Rack Piston Arbor (C-4175) into rack piston until it contacts worm shaft.

VALVE BODY & STUB SHAFT

Note. Valve body and stub shaft should not be disassembled unless necessary. If components are defective, valve body and stub shaft must be replaced as a unit. If "O" ring seal requires replacement, remove spool valve only.

Scheme 12

Scheme 12: Disassembly
  1. Lightly tap end of stub shaft against wooden block until cap (large end) of stub shaft is free of valve body. Remove stub shaft cap-to-wormshaft "O" ring. Pull stub shaft outward from valve body, no more than 1/4", until drive pin hole is visible. (Scheme 12) CAUTION: DO NOT force stub shaft or spool valve out of valve body.
  2. Disengage drive pin. (Scheme 12) Rotate and remove stub shaft from valve body. Remove spool valve from valve body. If spool valve becomes cocked, realign spool valve and remove. Carefully cut, remove and discard all "O" rings and Teflon rings. (Scheme 13)

Scheme 13

Scheme 13
  1. Wash all parts in solvent and blow dry. Check for leaks between stub shaft and torsion bar. Check for nicks and scores on stub shaft. Sand down with Crocus cloth, if possible. Check drive pin notch in valve body skirt for wear. Check stub shaft drive pin for damage.
  2. Lubricate spool valve with power steering fluid. Check spool valve fit in valve body, with "O" ring removed, by rotating spool valve in valve body. If valve does not rotate freely, replace complete valve. Valve assembly is balanced during assembly. If replacing any parts other than "O" rings or Teflon seals, replace complete assembly.

Note. Teflon seals may appear to be distorted after installation, but heat during operation will straighten them.

  1. Lubricate valve body components with power steering fluid. Install NEW "O" rings in seal grooves. Install NEW Teflon seals over "O" rings. DO NOT damage seals during installation.
  2. Lubricate replacement spool valve "O" ring with power steering fluid and install on spool valve. (Scheme 13) Carefully install spool valve in valve body.
  3. Push spool valve through valve body until stub shaft drive pin hole is visible on valve body and spool valve is even with notched end of valve body. Install stub shaft into spool valve and valve body.
  4. Align notch at top of stub shaft with pin in valve body. (Scheme 14) Press stub shaft and spool valve into valve body. Install "O" ring in groove on stub shaft.

Scheme 14

Scheme 14

Remove sector shaft seal ring. (Scheme 1) Remove steel washer, lower oil seal, steel washer and upper oil seal from housing. Press sector shaft bearing from steering gear housing.

Note. Sector shaft threads and splines should be covered with vinyl tape during installation to protect replacement seal lips.

  1. Lubricate steering housing bore, steel washers and oil seals with power steering fluid. Install sector shaft bearing in steering gear housing using Handle (C-4171) and Adapter (C-4178). Bearing should be installed until bearing is .030" (.76 mm) below shoulder of inner bore.
  2. Install upper oil seal (single lip seal) and steel washer. Oil seal lip should face toward steering gear housing, and must be installed only deep enough to allow for remaining oil seal, steel washer and ring to be installed. CAUTION: DO NOT install upper oil seal against inner bore surface of steering gear housing. Oil seals must be installed so each oil seal is separately seated in shaft bore.
  3. Install lower oil seal (double lip seal) and steel washer. Oil seal must be installed only deep enough to allow for steel washer and ring to be installed. Lips of both seals should face toward steering gear housing bore. Install retaining ring.

TORQUE SPECIFICATIONS

ApplicationFt. Lbs. (N.m)
Adjuster Plug Lock Nut80 (108)
Ball Guide Clamp Bolt10 (14)
Center Link-To-Pitman Arm Nut47 (64)
Flow Control Valve Fitting55 (75)
Idler Arm-To-Center Link Nut38 (52)
Idler Arm-To-Frame Bolt115 (156)
Mounting Studs35 (47)
Pitman Arm Nut (1)185 (251)
Rack Piston End Plug75 (102)
Sector Shaft Adjuster Screw Lock Nut36 (49)
Side Cover Bolt45 (61)
Steering Gear Housing-To-Frame Bolt105 (142)
Tie Rod Clamp Bolt26 (35)
Tie Rod Nut
9/16"55 (75)
5/8"75 (102)
Vacuum/Power Steering Pump Assembly-To-Engine Bolts57 (77)
Vacuum Pump-To-Power Steering Pump Nuts18 (24)
(1) Nut must be staked against pitman arm threads.
(1)Nut must be staked against pitman arm threads.

TORQUE SPECIFICATIONS