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STEERING GEAR (PUMPS, STEERING GEAR ARM

1. 18 Lubricate the rotor and slippers with clean power steering fluid and rotate the shaft to make sure the slippers do not bend 19 Replace the shaft seal and O ring seal on 19 32 STEERING GEAR PRESS RAM TOOL FRONT INSERT 63x685 Fig 68 Pressing the Front Insert into Pump Housing the front insert Lubricate the shaft seal O ring and shaft with power steering fiuid 20 After making sure the inner face on the front insert is smooth and free of burrs place the insert assembly on the shaft with care so that the shaft seal is not damaged by the end of the shaft 21 Support the pump housing in an arbor press and using a 1 inch socket with 14 inch drive align the center punch marks on the front insert and the pump body and press the insert into the pump hous MOUNTING BOLTSe x im epe a z ab 1 r x s PIVOT BOLT 61x255 Fig 69 Loosening the Pump Bracket Mounting Serews TORQUE WRENCH TOOL M ADAPTER TOOL MOUNTING BRACKET 61x256 Fig 70 Pump Belt Adjustment ing Fig 68 22 Install the spanner nut and tighten to the exact original position in the housing as indicated by the pin punch marks placed on the pump body and span ner nut at disassembly 23 Install the flow control valve as outlined under Flow Control Valve Installation 24 Install the pump pulley Fig 55 25 Install a
2. g Align the front wheels See Front Suspension h Replace the rear springs i Replace the parts necessary a Inflate the tires to recommended pressures b Balance as necessary See Wheels and Tires 19 34 Condition 23 Excessive Play or Looseness in the Steering Wheel 24 Hard Steering STEERING GEAR SERVICE DIAGNOSIS Continued MANUAL STEERING Possible Cause c Loose tie rod ends or steering connections d Worn or inoperative shock absorbers a Steering gear shaft adjusted too loose or badly worn b Steering linkage loose or worn c Front wheel bearings improperly adjusted d Steering arm loose on steering gear shaft e Steering gear housing attaching bolts loose f Steering arms loose at steering knuckles g Worn ball joints POWER STEERING a Tires not properly inflated b Low oil level in pump reservoir usually accompanied by pump noise c Loose pump belt d Improper caster and camber e Faulty pump power steering output low Correction c Inspect and repair as necessary d Replace the shock absorbers as necessary a Replace worn parts and adjust according to instructions b Replace worn parts See Front Wheel Alignment c Adjust according to instructions d Inspect for damage to the gear shaft and steering arm replace parts as necessary e Tighten the attaching bolts to 50 foot pounds torqu
3. d Press down on the piston to bottom the piston ring in the piston groove forcing the open ends of the ring out for ease of locking the ring The ring should be positioned with ring hooks in line with the ball guide plug STEERING GEAR 19 19 SME ADAPTER TOO 4 E 5 7 a 55x53 Fig 41 Installing the Gear Shaft Oil Seal 1 Place the piston assembly in a vertical posi tion worm shaft up in a vise equipped with soft jaws 2 Slide the cylinder head assembly ferrule up on the worm shaft inspect the worm shaft seal ring making sure the gap is closed to avoid damaging the ring as the cylinder head moves against the piston flange 3 Lubricate with Power Steering Fluid MoPar Part No 2084329 and install the following parts in order a Lower thrust bearing race thick b Lower thrust bearing ec Lower reaction spring with small hole over the ferrule d Lower reaction ring flange up so the ring protrudes through the reaction spring and contacts the reaction O ring in the cylinder head e Center bearing race f Upper thrust bearing g Upper thrust bearing race thin h Start the worm shaft thrust bearing nut do not tighten 4 Turn the worm shaft counter clockwise one half turn Hold the worm shaft in this position while tightening the unit to 50 foot pounds torque to pre stretch the worm shaft threads CAUTION If the worm shaft is turned more than one half turn the cylinder he
4. 1 Lubricate a new small 0O ring and install it over the adjusting screw into position at the top of the gear shaft cover 2 Lubricate an O ring and gear shaft cover with petrolatum and install the O ring in the cover groove 3 Install the adjusting screw lock nut but do not tighten Steering Gear Housing Disassembly 1 Attach the steering gear housing in the hold ing fixture Tool C 3323 and place the holding fixture in a vise NOTE The gear shaft oil seal should be removed with the gear shaft installed in the housing 2 Remove the gear shaft outer oil seal with adapter SP 3056 and Tool C 3350 Fig 39 as follows a Slide the threaded position of adapter SP 3056 over the end of the gear shaft b Install the nut section of Tool C 3350 on the shaft c Maintain pressure on adapter SP 3056 with the nut of Tool C 3350 while turning the adapter into the seal until it has bottomed in the seal ADAPTER TOOL Fig 40 Removing the Housing Lower Bushing d Install the two half rings and retainer over both portions of the tool e Turn the nut counter clockwise as the hexagon nut is removed from the shaft the seal will be pulled from the housing 3 Remove the oil seal snap ring and oil seal back up washer and perform operation 2 to remove the inner oil seal 4 If necessary to remove the housing bearings use puller Tool C 3332 with adapter SP 3062 Fig 40 as follows a Engage the ja
5. B Dor MN Fig 67 installing the Shaft and Roto Assembly NOTE Inspect the springs to make sure they are in the pockets and in an upright position under the slip per Fig 65 13 Using a washer of the dimensions shown in Figure 66 drop it over the pulley end of the shaft This washer is used to keep the slippers flush with the end of the rotor NOTE If is important that the slippers remain flush with the end of ihe rotor ihroughout the assembly operation 14 Insert the shaft and rotor assembly with flat washer tool and slipper retaining tool into the pump cam insert so that the slippers and rotor are inside the cam with the end of the shaft resting against the back face in the housing Fig 67 CAUTION Do Not attempt to insert the pump shaft into the bearing at this time 15 Hold the washer against the rotor with a screw driver while removing the wire retaining tool making sure that the slippers remain flush with the end of the rotor 16 Line the pump shaft with the lower bearing and push the shaft rotor and slippers all the way into the housing until the rotor is flush with the end of the cam insert NOTE The slipper ends may hang up on the center openings in the cam insert If this should occur rotate the shaft while installing will overcome this condition 17 Remove the special flat washer Make sure that the springs are in place by rotating the pump shaft and looking through the notch in each slipper
6. Remove the steering jacket support nut with SPANNER NUT 58x38 Fig 29 Removing the Steering Column Support Nut STEERING GEAR 19 15 Fig 30 Removing the Power Train Tooi C 3634 Fig 29 9 Firmly instal a suitable drift through the hole in the jacket support to engage the groove in the worm shaft thereby locking these two parts to gether Fig 30 10 While holding the drift pry on the piston teeth with a screwdriver using the gear shaft as a fulcrum and remove the complete power train NOTE By this procedure the worm will be all the way into the piston and the power train parts will be resting against the piston flange It is imperative that the cylinder head center race and spacer as sembly and the jacket support be maintained in close contact with each other This will prohibit the teflon sealing ring on the worm shaft from becoming dis engaged from its mating sleeve retained in the cylin der head It will also eliminate the possibility of the reaction rings becoming disengaged from their grooves in both the cylinder head and the column jacket support 11 Remove the gear shaft assembly from the housing and remove the steering gear housing from the vise Power Train Disassembly 1 Place the power train in a vise equipped with soft jaws to avoid damaging the piston assembly CAUTION Do not turn the worm shaft more than one half turn during disassembly 2 Remove the column jacket support tan
7. and return connections by turning the steering tube coupling from one extreme of travel to the other 2 Remove the coupling pin CAUTION Support the coupling when driving the pin in or out to avoid damaging the worm shaft and bear ings VALVE ASSEMBLY 58x34 O RINGS Fig 27 Removing the Valve Body Assembly Ra LEER o HOLDING FIXTURE JACKET TUBE SUPPORT 58x36 Fig 28 Removing the Gear Shaft Cover Nut 3 Remove the valve body housing attaching screws and remove the valve body and the three 0 rings Fig 27 4 Remove the valve lever and spring Pry under the spherical head with a screwdriver Use care not to collapse the slotted end of the valve lever as this will destroy the bearing tolerances of the spherical head 5 Loosen the gear shaft adjusting screw lock nut to facilitate removal and remove the gear shaft cover nut with Tool C 3633 Fig 28 CAUTION Oil will be expelled when the gear shaft and cover are withdrawn from the housing 6 Rotate the worm shaft to the full right turn position then return the worm shaft to the center of travel This will place the piston in the center posi tion Fig 17 Withdraw the gear shaft until the sector teeth clear the housing Rotate the shaft 190 degrees and allow the ends of the teeth to rest on the housing 7 Turn the worm shaft to full right turn posi tion to compress the power train parts and then remove the coupling 8
8. in stall the gear shaft outer bearing into the housing with Tool C 3786 Fig 12 Drive the outer lower bearing to within 4 inch or end of counterbore Drive the inner upper bearing Fig 13 flush with the hore face with Tool C 3786 Fig 12 Installing the Gear Shaft Housing Outer Bearing Steering Gear Assembly 1 Insert the worm and the shaft into the hous ing with the bearings and cups 2 Install the shim and the lower housing cover making sure the bearings are seated NOTE When tightening the cover turn the worm tube to be sure no bind exists 3 Final tightening of the cover screws should cause the end play to disappear with torque of to pound required to rotate the tube when measured with a pull scale applied at the rim of the steering wheel Add or remove shims in the event a bind or excessive end play occurs Shims are available in 003 006 and 011 inch 4 Install the gear shaft 5 Before installing the cover turn the adjusting screw all the way out 6 Rotate the wormshaft in one direction to the end of its travel Rotate the wormshaft in the other direction to the end of its travel counting the turns Rotate the wormshaft back of the full number of turns Fig 11 41nstalling the Gear Shaft Oil Seal Fig 13 Installing the Gear Shaft Housing Inner Bearing OO a Eo 7 Turn the adjusting screw clockwise unt
9. tool body will force the seal assembly from the pump CAUTION The pulley end of the shaft should be ex amined for sharp burrs or corners and smoothed with a stone or fine emery cloth This wil prevent seal damage when the new seal is installed Do Not stone or emery the area on the shaft that the seal lip con tacts PULLEY 63x665 Fig 55 lnstalling the Pump Pulley 19 28 STEERING GEAR 7 Install the new seal with the lip of the seal to ward the pump Use Tool C 3782 to drive the seal flush with the insert Fig 54 8 Support the pump body on the holding fixture Tool C 3643 with the tool dowel pins in the pump bolt holes so that the pressure will be absorbed by the lower end of the pump shaft Fig 55 CAUTION The pump must be supported in a manner in which all pressing force will be applied to the shaft only otherwise the pump body and rotor will be damaged 9 Install the pulley with a heavy duty arbor press Press on the pulley hub only until the hub is flush with the end of the pump shaft 10 Lubricate the large 0 ring and the reser voir cap screw gasket and install both on the pump body 11 Tighten the reservoir and the pump brackets Tighten the screws to 16 foot pounds torque 123 Install the steering pump and test belt adjust ment as outlined under Cooling System 16 POWER STEERING PUMP DISCHARGE FITTING FERRULE REPLACEMENT 1 Wipe away all dirt around the discharge fitting
10. Adjustment c Replace the belt and adjust d Lubricate and repair as necessary e See Fuel Specifications f Work the steering wheel from right to left until the air is expelled STEERING GEAR 19 37 SERVICE DIAGNOSIS Continued POWER STEERING Condition Possible Cause Correction g Faulty power steering pump g See Diagnosis Hard Steering cor rection e h Gear malfunction h Adjust and repair as outlined un der Hard Steering condition and correction g 3l Noises a Buzzing noise in neutral and stops when a Noisy pump make pressure test the steering wheel is turned and repair as necessary Damaged hydraulic lines or interference of the hoses with components at tached to the fender shield Air in system work steering wheel from right to left until the air is expelled b Chuckling noise Causes as follows b Correct as follows 1 Improper gear shaft adjustment l See Gear Shaft Adjustment 2 Improper worm shaft thrust bearing 2 Remove steering gear disas adjustment semble inspect and reassemble See Center Bearing Preload 3 Coupling loose on the worm shaft 3 Inspect worm shaft splines for wear Also inspect retaining pin for tighteness c Metallic clatter or tapping noise c Replace the back pressure valve 32 Low Oil Pump Pressure d Knocking condition at the bracket stop when the engine is running e Loose pump belt POWER STEERING PUMP a
11. Lubricate with 2084329 power steering fluid and install the control valve over the control valve spring and into the bore When all valve lands have cleared the retaining ring groove area work the control valve back and forth against spring pressure until the valve operates smooth and freely 4 Install a new O ring on the end plug 5 Lubricate the end plug and 0 ring and install the end plug with the machined projection out 6 Install the plug retainer ring with the sharp edge of ring up 7 Install the relief valve STEERING GEAR 19 29 Olt SEAL INSERT y PUNCH MARKS PUMP BODY Dona TON dia 63x671 ot Fig 59 Center Punch Marks on Pump Body Spanner Nut and Front insert 8 Install pulley Fig 55 9 Install a new pump body O ring new reser volr gasket and reservoir and brackets 18 SLIPPER SPRING REPLACEMENT 1 Remove the bracket and reservoir 2 Remove the pump pulley Fig 52 3 Use a center punch to mark the position of the spanner nut and front insert in the pump hous ing Fig 59 to insure that the front insert and span ner nut are returned to the exact same position at reassembly Fig 60 Removing the Spanner Nut 19 30 STEERING GEAR PRESS RAM 63x675 Fig 61 Removing the Shaft Rotor and Front Insert 4 Use a inch drift to loosen and remove the spanner nut Fig 60 5 Support the pump housing so that the front in sert
12. PLUG AND SNAP RING Do Fig 52 Removing the Pump Pulley move the belt from the pulley 2 Place a container under the pump and discon nect both hoses at the pump Cap ends of the hoses and secure the hoses high enough to prevent loss of fluid 3 Remove the boits attaching the pump bracket to the engine and remove the pump assembly Oil Seal Replacement 1 Clean the exterior of the pump before disassem bly 2 Remove the filler cap and drain the reservoir 3 Remove the brackets reservoir screws gasket and 0 ring 4 Using spacer washers between the front brack et and the pump reinstall the front bracket for use as a holding fixture Clamp the bracket in a vise Fig 52 5 Remove the pulley with Tool C 3615 as follows a Engage one half collar under the flange of the Fig 53 Removing Pump Shaft Oil Seal Typical 19 27 STEERING GEAR Fig 54 lnstalling the Pump Oil Seal Typical pulley hub b Position the screw shaft and nut with the flange section inside the half collar c Engage the other half collar under the pulley hub and over the flange of the screw shaft nut and install the retainer sleeve over both half collars d Hold the nut from turning and turn the screw inward to remove the pulley 6 Remove pump shaft oil seal by threading Tool C 3783 far enough into seal to engage the metal por tion of the seal Fig 53 Turning the puller center screw while holding the
13. Steering wheel column jacket and f steering nut improperly aligned Steering gear malfunctions 1 Improper gear shaft adjustment 2 Column support spanner nut loose 3 Faulty or damaged valve lever 4 Improper worm thrust bearing adjustment 5 Faulty or damaged cylinder head worm seal ring or faulty worm piston ring 6 Burrs or nicks in the reaction ring grooves in the cylinder head or column support 7 Dirt or chips in the steering gear unit 8 Rough or catchy worm in the piston assembly a Tires not properly inflated f Repair and lubricate as necessary g Adjust or repair as follows 1 See Gear Shaft Adjustment 2 Remove steering gear repair as necessary 3 Inspect for leakage at the lower sector shaft oil seal the sector shaft cover 0 4 Remove the steering gear and repair as necessary a Inflate the tires to recommended pressures b Repair and lubricate as necessary c See Front Wheel Alignment Front Suspension Section d Remove the jacket tube and re place bearings e See Installation of Steering f Gear Adjust or repair as follows 1 See Gear Shaft Adjustment 2 Remove the steering gear disas semble inspect and reassemble as outlined in this section 3 Remove the steering gear and repair as necessary 4 Remove the steering gear dis assemble inspect and reassemble See Center Bearing Preload A
14. at the dash panel and at the column clamp to 95 inch pounds torque 5 Tighten the steering column to the instrument panel clamp bolts to 15 foot pounds torque 6 Tighten the lower steering column clamp boit nut to 200 inch pounds torque 7 Reinstall the steering gear arm washer and nut Tighten to 120 foot pounds torque 19 10 STEERING GEAR 4 ADJUSTMENT OF THE ROLLER TOOTH AND WORM In the Vehicle 1 Disconnect the steering gear arm at the link 2 Rotate the steering wheel to mid position and then check for backlash by attempting to move the Steering gear arm back and forth 3 If backlash exists loosen the gear shaft ad justment screw lock nut and tighten the adjusting screw enough to eliminate free play Be sure the roller shaft and the worm do not bind Recheck the backlash 4 Tighten the adjusting screw lock nut while holding the adjusting screw from turning 5 Connect the steering gear arm at the link 5 STEERING KNUCKLES Removal 1 Place a jack under the lower control arm as near to the wheel as possible Remove the wheel tire and drum Be sure the brake shoes are covered to prevent dirt or grease from soiling the lining 2 Remove the cotter pins nuts and lockwashers that attach the steering arm and brake dust shield to the steering knuckle Remove the steering arm brake dust shield brake supports and shoes from the steering knuckle as an assembly but leaving the brake hose attached Do
15. clearance hole in the steering gear housing NOTE Place a feeler stock 0015 inch to cover the aligning notch in the steering gear housing fo pro tect the O ring seals when installing the gear train CAUTION Make sure the cylinder head is bottomed on the housing shoulder Fig 18 Do not release pressure on the power train Fig 30 until all the parts are positioned in the steering gear housing 2 Align the valve lever hole in the center bear ing spacer exactly with the clearance hole in the housing using a suitable drift as an aligning tool NOTE Tool should not be removed until the spanner nut is securely tightened 3 Install the column support spanner nut and tighten the nut 110 to 200 foot pounds torque with Tool C 3634 Fig 29 4 Set the piston at the center of travel and in stall the gear shaft and cover assembly se that the sector teeth index with the piston rack teeth Make sure the 0O ring is properly positioned in the face of the cover Fig 38 5 Install the cover spanner nut and tighten the nut 110 to 200 foot pounds torque with Tool C 3633 Fig 28 6 Install the valve lever double bearing end first into the center bearing spacer through the hole in the steering housing so that the slots in the valve lever are parallel to the worm shaft in order to en gage the anti rotation pin in the center bearing race NOTE Turn the worm until the piston bottoms in both directions and observe the action o
16. insulator up out of the counterbore in the bear ing housing Remove the insulator from the bearing 5 Using snap ring pliers Tool C 3128 remove the bearing upper snap ring from the upper groove in the steering shaft 6 Using bearing puller Tool C 3891 remove the steering column upper bearing as shown in Figure 4 7 Remove the lower snap ring and slide the steer ing shaft and coupling assembly down and out of the steering column jacket assembly 8 Remove the column jacket lower seal from the steering shaft LIP TYPE SEAL 61x31 Fig 5 Nylon Rings and Lip Type Seal Disassembled View STEERING GEAR 19 5 Steering Column Assembly 1 Position the spring washer on the ledge pro vided in the top end of the steering column jacket 2 Place the two bearing housing retaining bolts in position in the housing and just start the nuts on them 3 Stand the column assembly upright and lower the bearing housing into position engaging the bolt heads in the slots in the column jacket 4 Tighten the two retainer bolt nuts alternately and evenly in steps to prevent unseating the bolt heads from the slots Tighten to 95 inch pounds torque 5 Position the isolator in the inside diameter of the floor plate and install the floor plate on the steer ing column with the insulated side down NOTE Before installing the floor plate and isolator on the column jacket lubricate the inside diameter of the isolator wit
17. is clear and use a smooth inch diameter bar Fig 61 press the shaft rotor and front insert out of the pump housing CAUTION Be careful not to damage the pump rear bearing 6 Examine the parts for broken edges or deep scoring especially on the rotor and slippers If either of these conditions are present then the pump as sembly less pulley and reservoir must be replaced Small nicks or burrs may be smoothed with a fine hone NOTE The cam insert has two machined notches one large and one small on the inside surface these are not to be interpreted as deep scoring Fig 62 Slipper Retainer Wire Retainer Tool Installed on Rotor WIRE TOOL i 63x677 Fig 63 installing the Slipper Springs Typical 7 Smooth off burrs or corners on the pulley end of the pump shaft this will prevent shaft oil seal damage when a new seal is installed CAUTION Do not stone or emery the area on the shaft that the seal lip contacts 8 If all parts are in a serviceable condition dis card all eight slipper springs even if they appear to be in good condition 9 Thoroughly flush and clean all parts with clean solvent NOTE It is essential that cleanliness be observed throughout the pump assembly 10 Using a piece of soft steel wire 25 inches long make three turns around the center of the rotor and fasten the wire as shown in Figure 62 Bend the ends of the wire towards the pulley end of shaft Do not make the wir
18. leakage in the steering gear valve body a Oil level low in pump reservoir b Loose pump belts c Oil on pump belt d Binding steering linkage e Engine idle too slow f Air in the system b See Front Suspension Front Wheel Alignment c If vehicle steers to the left move the steering valve housing down on the steering housing If vehicle steers to the right move the steer ing valve housing up on the steer ing housing d Remove the steering gear and re place or repair as necessary e Remove the steering gear and re pair as necessary a See Gear Shaft Adjustment b Remove the steering gear disas semble inspect and reassemble as outlined in Group 19 c Remove the steering gear disas semble inspect and reassemble see Center Bearing Preload As sembly of Power Train d Inspect the wormshaft splines for wear a Remove the steering gear disas semble inspect and replace the parts as necessary b See Assembly of the Power Train c Replace the worm and piston as sembly d Remove the steering gear and re pair as necessary a See Pump Belt Adjustment b Perform the Pump Pressure and Flow Tests also refer to correc tion e in Diagnosis under Hard Steering c See Assembly of Power Train d Replace the worm and piston as sembly e Replace the steering gear valve body assembly a See Fluid Level b See Pump Belt
19. not allow the assembly to hang by the brake hose 3 Remove the ball joint studs from the steering knuckles Lift the steering knuckle out and away from the vehicle IDLER ARM THE ROD END ASSEMBLY TIE ROD END COVER KNUCKLE ARM Installation 1 Position the upper and lower ball joint studs into the steering knuckle and install the lock washer and nuts Tighten the upper ball joint stud nut to 100 foot pounds torque on Models TC 1 and TC 2 and 135 foot pounds torque on Models TC 3 and TY 1 Tighten the lower ball joint stud nut to 115 foot pounds TC 1 and TC 2 135 foot pounds TC 3 and TY 1 and install the cotter pin 2 Slide the brake dust shield support and shoe assembly over the knuckle and into position Install the lockwashers and nuts on the upper rear and lower front bolts 3 Install the upper front and lower rear bolts through the dust shield and steering knuckle Posi tion the steering arm over the bolts Install the lock washers and nuts Tighten the steering knuckle to brake support bolts 55 foot pounds torque and the steering knuckle to steering knuckle arm bolts 80 foot pounds torque Install the cotter pins 4 Remove the covering from the brake shoes Install the wheel tire and drum assembly Adjust the front wheel bearings Refer to Paragraph Front Wheel Bearing Adjustment in the Front Suspen sion Group 2 6 STEERING LINKAGE Figure 16 Removal When removing the tie rod ends
20. on the arm and place the shoe of the puller behind the steering arm Fig 25 Tightening the tool center screw against the gear shaft wil pull the steering arm from the gear shaft CAUTION Do not remove the steering arm by prying with a lever or striking with a hammer as serious steering gear internal damage will result 23 Disconnect the hydraulic brake line at the master cylinder and the brake tee and remove the line not necessary on Imperial Models 24 Disconnect the pressure and return hoses at the steering gear Fasten the ends of the hoses above ns CE 61x246 Fig 21 Removing the Steering Wheel Fig 23 Removing the Directional Switch 19 14 STEERING GEAR WHEEL NUT STEERING TUBE SNAP RING WASHER SPRING 60 x 13 Fig 24 Jacket Tube Installation imperial the oil level in the reservoir Cap the ends of the hoses Cap the fittings on the steering gear 25 Slide the jacket tube up and off the steering gear through the driver s compartment Remove the jacket tube upper spring and retainer Remove the rubber insulator boot and horn ground strap 26 Remove the steering tube coupling pin two plastic inserts horn ground strap Fig 26 rubber insulator and the upper steering tube 27 Remove the gear housing to frame bolts washers and alignment wedge Remove the nuts and washers attaching the master cylinder to the brake booster and slide the master cylinder off the stud
21. studs into the idler arm and steering arm and tighten the nut to 40 foot pounds torque Insert the cotter pins 3 Connect the tie rod ends to the steering knuckle arms Tighten the nuts to 40 foot pounds torque Slide the stone protector into position and in stall the cotter pins 4 Measure and adjust the front wheel toe in See Front Suspension Group 2 PART 2 POWER STEERING The power steering gear consists of a gear housing Fig 17 containing a gear shaft with sector gear a power piston with gear teeth milled into the side of the piston is in constant mesh with the gear shaft sector and a worm shaft connects the steering wheel to the power piston The worm shaft is geared to the piston through a recirculating ball contact Fig 18 SERVICE DIAGNOSIS 7 GEAR SHAFT ADJUSTMENT In the Vehicle 1 With the gear shaft on center loosen the gear shaft adjusting screw lock nut turn and tighten the adjusting screw until backlash just disappears Tighten the screw 114 turns from this position and while holding the adjusting screw in this position tighten the lock nut CROSS SHAFT SECTOR GEAR POWER PISTON SBX198A Fig 17 Steering Gear Housing Sectional View NOTE This is a temporary adjustment fo insure that the piston rack and sector teeth are in full align ment 2 Operate the unit manually for a minimum of 180 degrees from the center in each direction meas ured at the worm shaft 3 Sta
22. the disc is less than 4 inch with the column jacket tube clamped in place 2 STEERING GEAR Removal 1 Disconnect the battery cable at the battery negative terminal 2 Remove the steering arm nut and washer and remove the steering arm from the steering gear cross shaft with puller Tool C 3646 3 Remove the bolt and washer attaching the lower coupling to the steering gear worm shaft 4 Loosen the steering jacket clamp screw at the instrument panel Do Not Remove 5 Tap the coupling assembly upward and care fully lift the steering column and jacket up and off the end of the worm shaft 6 Remove the three nuts washers and bolts at taching the steering gear to the frame side rail 7 Remove the gear through the engine compart ment by lowering the upper end of gear towards the drivers compartment then raise rear end of the gear up and remove the gear Disassembly Fig 1 1 Remove the gear shaft oil seal from the steer ing housing with puller Tool C 3350 See Gear Shaft Oil Seal Replacement If the shaft is corroded or dirty clean the portion between the oil seal and the serrations to avoid binding in the bearings NOTE Position gear shaft bearing remover and in STEERING GEAR 19 7 HA US Me pert FE D ch o p im a m E AMET 7 wA o igni J PX 20 re pk bi TINA IAO MAG G i Fig 7 Removing the Worm Shaft Oil Seal st
23. LE COUPLING MASTER SERRATION PIC 61X238 Fig 14 Aligning the Steering Gear with the Flexible Coupling STEERING GEAR 19 9 a toos ga gum HE MNT cx ge PP Aes En M ji Ne p v ims si ae as Tu T a E z te 0 exse 3 ha Mazej aue JA Fig 15 Steering Gear Alignment 6 1X239 7 Position the flexible coupling bolt hole in line with the groove on the worm shaft and install the bolt and lockwasher 8 Tighten the bolt 30 to 35 foot pounds torque NOTE The horn ground is attached to the under side of the coupling by two bolts to complete the cir cuit 3 STEERING GEAR ALIGNMENT Fig 15 Inspect the steering gear shaft for alignment in the steering column seal as follows 1 Loosen the steering column clamp bolts at the instrument panel 2 Loosen the lower column clamp bolt and the support bracket at both the dash panel and at the column clamp NOTE A rubber lip type seal is positioned between the upper hub of the flexible coupling and the jacket tube The outer groove of the seal must be firmly in stalled on the jacket tube and the two nylon rings Fig 15 and the lip of the seal must be well lubri cated with a wheel bearing grease 3 Hold the steering column so it is centered plus or minus Ls inch on the tube while aligning the col umn support bracket to the dash panel and lower column clamp 4 When the column is properly located tighten the support bracket stud nuts
24. Pump be t loose b Pump pulley loose c Oil level low in pump reservoir d Pressure relief valve spring weak or relief valve stuck in open position e Flow control valve stuck f Worn pump rotor slippers or broken and distorted springs cushion d Rubber stop worn or missing from pump bracket e Belt not properly adjusted or worn to the extent that belt tension can not be properly adjusted a See Pump Belt Adjustment b Replace the pulley measure the pump diameters as follows Shaft diameter 8120 8125 Pulley inside diameter 8095 8105 If shaft is damaged replace pump c See Fluid Level d Replace the relief valve and per form Pump Pressure Test e Repair as necessary Refer to Flow Control Valve Removal and Installation and Correction under Hard Steering f Repair as necessary See Hard Steering Correction e 19 38 Condition 33 High Pump Pressure 34 Leaks STEERING GEAR SERVICE DIAGNOSIS Continued POWER STEERING PUMP Possible Cause a Wrong relief valve b Relief valve clogged with foreign matter dirt metal chips etc a Reservoir over filled NOTE Operating the steering gear manually when the engine is not running will cause the steering gear to displace the fiuid from the steering gear housing which will then be forced out of the pump filler cap vent giving a false indication of fluid leakage b Pressure and retu
25. STEERING GEAR 19 1 GROUP 19 STEERING GEAR PUMPS STEERING GEAR ARM IDLER ARM CONTENTS PART 1 MANUAL STEERING Page Page Roller Tooth and Worm Adjustment 10 Stesnna OBA sein aM EE a 6 Service Diagnosis iskani bebe 33 Steering Knuckles 10 SBecificilionE s oet v TR aes owen Ste d ns Steering Linkage 10 Steering Column 4 Final Test Adjustment and Specifications 22 Service Diagnosis 34 Gear Shaft Adjustment 11 Specifications PE RR d RC A s 1 Power Steering Gegr 11 Ste amp nn Cear 62 os ni a hee KO RE REESE 22 Powar IB epska Die ES PEE na Md d 19 Belt Adjustment voe RATS d RR eR m eee Rd 33 Pressure Task iia sese Ede SR ESPERE RI Rud 25 Flow Control Valve 28 Pump Flow Test iuo o IURE CE AC o deoa 26 Fluid Level uita erede dae chee eas palaces 25 i l Service Diagnosis 37 Power Steering Pump 26 ate DA Slipper Spring Repiccement 29 Power Steering Pump Discharge Fitting Specificati ns Ferrule Replacement 28 a k k a ka a SPECIFICATIONS MANUAL STEERING Worm and Three Tooth Roller TE ni P Se nece HR RE ao b SORE Eh ee EI O Sod uid s RUP EON RC AR 20 4 to 1 Gade Shaft Begaf
26. a W inch flat end punch on the center line of the worm shaft and perpendicular to the worm shaft and at a slight angle to the nut flange Fig 45 b Strike the punch a sharp blow with a hammer and recheck the pre load NOTE If the adjusting nut moved during the stak SCALE TOOL FERRULE 58x65 eh wt Fig 44 Adjusting the Center Bearing Race Preload STEERING GEAR 19 21 ing operation it can be corrected by striking the nuf a glancing blow in the direction required to re gain proper pre load c After the proper pre load stake the nut at three more locations 90 degrees apart around the upper part of the nut d To test the total staking tighten the nut to 20 foot pounds torque in either direction If the nut does not move the staking operation is satisfactory IMPORTANT Retest the pre load adjustment the torque of 8 16 inch ounces must remain after the adjusting nut is securely locked 7 Install the center bearing spacer assembly over the center bearing race and engage the dowel pin of the spacer in the slot of the race and the slot of the spacer entered over the cylinder head ferrule NOTE This will align the valve lever hole in the center bearing race with the valve lever hole in the center bearing spacer assembly 8 Install the upper reaction ring on the center bearing spacer with the flange down against the spacer 9 Install the upper reaction pressure spring over the reacti
27. ad sleeve will clear the oil seal ring on the worm shaft Always position the worm shaft oil seal ring befofe bottoming the cylin der head against the piston top flange to avoid dam aging the oil seal ring 5 Loosen the adjusting nut Place several rounds of cord around the center bearing race Fig 44 Make a loop in one end of the cord and hook the loop of a distributor breaker arm spring scale Tool MTU 36 in the eord loop Pulling the cord will cause the RETAINER SEAL BEARING WORM W PISTON HOUSING O RING SHAFT SCREW W ASHER BEARING NUT COUPLING O RING SPRING PLUNGER O RING SEAL o RING ADAPTER NUT GASKET NUT INSULATOR SPRING RING VALVE ASSEMBLY BEARING SUPPORT GROUND BEARING 60x18 A Fig 42 Steering Gear Disassembled View 0cC 61 4vio9 9NRiilS y PISTON RING WORM SHAFT fi PISTON 19i 3 A Pas Fig 43 Removing the Piston Ring bearing race to rotate Retighten the worm bearing adjusting nut while pulling on the cord with the scale If the adjusting nut is tightened properly reading on the scale should be 8 to 16 ounces 12 ounces preferred while the bearing race is turning CAUTION Place a support under the adjusting nut during the staking operation to avoid brinelling the piston and the worm bearings 6 Stake the upper part of the worm shaft ad justing nut into the knurled area of the shaft as follows a Hold
28. aller arbor Tool C 3786 over the gear shaft threads and while withdrawing the gear shaft follow with the arbor This arbor will keep the bearing rollers from dropping out of their cages 2 Remove the gear shaft adjusting screw lock nut cover gasket and the steering gear shaft assem bly 3 Remove the cover and shim from the bottom of the housing 4 Remove the steering shaft and worm assem bly bearings and cups 5 If it is necessary to remove the housing bear ings drive the bearings from the steering gear hous ing with the gear shaft bearing remover and installer arbor Tool C 3786 Inspection Clean all parts in a suitable solvent Inspect all parts for wear TOOL SEAL PROTECTOR Fig 8 installing the Oil Seal Protector Fig 9 lnstalling the Worm Shaft Oil Seal NOTE Assemble parts without lubrication Lubri cation should be done after adjustments are com pleted The needle bearings are grease packed from the factory If either of the worm thrust roller bearings are damaged replace both bearings Use new oil seals Worm Shaft Oil Seal Replacement 1 Thread Tool C 3819 far enough into the oil seal to engage the metal portion of the seal Fig 7 Turning the tool center screw while holding the tool body will withdraw the seal assembly from the hous ing bore 2 Place the oil seal protector of Tool C 3821 over the splines of the steering worm shaft and slide the oil seal over the protecto
29. and tighten the high pressure hose tube nut to 24 foot pounds torque 2 Restart the engine and steer car from stop to stop to build up pressure If the discharge fitting is leaking remove the high pressure hose from the pump and examine the tubing flare for nicks scratches or other damage If the flare or nut is damaged replace the high pressure hose 3 Examine the pump housing in the discharge z EXTRACTOR Fig 56 Installing the Ferrule Extractor SS HIGH PRESSURE HOSE FRONT INSERT f FLARE NUT SPANNER dg NUT FERRULE METERING INSERT SLIPPER BEARING SPRING O RING bh ue RELIEF VALVE RESERVOIR 63x668 Fig 57 Pump Cut Away View area to be sure that the housing has not been damaged by cross threading or over tightening the flare nut If the housing is cracked or if the threads are damaged the pump must be replaced 4 Remove the pump from the vehicle 5 Clamp the pump in a vise with the discharge opening in the down position this will prevent any chips from falling into the pump 6 Use a No 4 screw extractor E Z Out Turn the extractor into the ferrule Fig 56 then rock the extractor slightly to remove the ferrule Perform this operation carefully so as not to damage the threads on the housing 7 Clean out the discharge bore of any foreign material brass chips dirt ete 8 Center the new ferrule with the tapered end up in the housing bore The ferrule i
30. ate the unit manually for a minimum of 180 degrees from center in each direction measured at the worm shaft d With the hydraulic power applied to the unit and with the gear shaft on center plus or minus 2 de grees readjust the gear shaft backlash This will re quire loosening the adjusting screw until the back lash is evident Retighten the adjusting screw until the backlash just disappears Continue to tighten 38 ADJUSTING SCREW to 15 turn from this position and tighten the lock nut to 50 foot pounds torque to maintain this setting e Stariing from a point at least one full turn of the worm shaft either side of center the torque at the gear shaft required to turn the unit through cen er at 2 rpm in each direction shall not exceed 25 foot pounds or vary more than 5 foot pounds from left to right Perform this operation carefully to prevent a lockup in the steering gear f Adjust the torque evenly by moving the steering valve assembly by tapping gently on the back pres sure valve body attaching screws to move the valve body up on the steering housing and tap on the end plug to move the valve body down the housing NOTE if the torque is greater to the right move the control valve body Down If the torque is greater to the left move the valve body Up After positioning the valve to obtain equal torque tighten the valve body attaching screws to 15 foot pounds torque to maintain this setting g With the unit at or
31. bracket will be resting against the rubber stop in the adjustment bracket Fig 71 SERVICE DIAGNOSIS MANUAL STEERING Condition 20 Hard Steering b Insufficient lubricant in the steering Possible Cause a Low or uneven tire pressure Correction a Inflate the tires to recommended pressures b Lubricate as necessary gear housing or in steering linkage c Steering gear shaft adjusted too tight d Front wheels out of line e Steering column misaligned 21 Pull to One Side Tendency of the Vehicle to veer in one direction only a Incorrect tire pressure c Dragging brakes d Improper caster and camber e Incorrect toe in f Grease dirt oil or brake fluid on brake linings g Front and rear wheels out of alignment h Broken or sagging rear springs i Bent suspension parts 22 Wheel Tramp Excessive Vertical Motion of Wheels a Incorrect tire pressure brake drums b Wheel bearings improperly adjusted b Improper balance of wheels tires and c Adjust according to instructions d Align the wheels See Front Sus pension e See Steering Gear Alignment a Inflate the tires to recommended pressures b See Front Wheel Bearing Adjust ment c Inspect for weak or broken brake shoe spring binding pedal d See Front Wheel Alignment e See Front Wheel Alignment f Inspect replace and adjust as necessary
32. dy and remove the back pressure control valve assembly 2 Compress the pressure control valve spring and remove the retainer pin spring pressure control valve piston and back pressure valve cushion spring 3 Carefully shake out the steering valve piston Inspect the valve for nicks burrs and scores NOTE If the steering valve or valve housing is damaged replace the valve and housing assembly Do not remove the valve end plug unless inspec tion indicates a leak at the seal Smal burrs and nicks may be removed with crocus cloth if extreme care is used not to round off the sharp edge portion of the valve The sharp edge portion is vitally important to the operation of this valve Clean the valve bodies and valve pistons thor oughly in clean solvent Blow out all passages and blow parts dry with dry compressed air Lubricate the pistons and bores with Power Steering Fluid MoPar Part No 2084329 Assembly 1 Install the steering spool valve into the valve housing so that the valve lever hole is aligned with the lever opening in the valve body The valve must be perfectly free in the valve body without sticking or binding 2 Install a new seal and end plug if removed Tighten the plug to 25 foot pounds torque 3 Install the back pressure valve cushion spring 19 18 STEERING GEAR ADJUSTING SCREW STEERING SUR NUT CROSS O RING SHAFT ADJUSTING COVER NUT 58x283 Fig 38 Steering Gear Housing Sectiona
33. e f Tighten according to torque specifications g Replace the ball joints as neces sary See Front Suspension a Inflate the tires to recommended pressures b See Fluid Level Power Steering Pump c See Belt Adjustment d See Front Wheel Alignment Front Suspension Section e Perform the Pump Pressure and Flow Tests NOTE When the power steering pump fails to give proper steering assist the trouble is usually caused by foul ing of the flow control valve caus ing it to stick in the open or by pass position This fouling can be caused by gum deposits pieces of broken slipper springs burrs or foreign material pieces of rub ber dirt or maching chips If no fouling of the flow control valve is evident or if the flow control valve contains pieces of colled wire broken slipper spring the pump should be disassembled for pos sible slipper spring replacement Condition STEERING GEAR 19 35 SERVICE DIAGNOSIS Continued POWER STEERING Possible Cause Correction 25 Poor Recovery from Turns 26 Leads to Either Side f Steering linkage binding g Steering gear malfunctions l Gear shaft adjustment too tight 2 Faulty or damaged valve lever 3 External leakage 4 Excessive internal leakage a Tires not properly inflated b Steering linkage binding c Improper wheel alignment d Damaged or faulty steering tube bearing e
34. e La a a ee 40 Steering Idier Arm Bolt Nut si csuck a eee ee er a A RR RUE E S Gee Se god Meena ee 60 POWER STEERING Pressure Control Valve Body Screws 2 0 0 0 ee ttn ees 10 Pino Inl t Filfingu iier Hae eke a ee are OE ERR Ws Se Sh ee ae eee S ee a 30 Reservoir fo Pump Body Bolhi is i diebus RA a Eph an n dud a tei h RO CRAVE GSC en 10 15 Steering Wheel Nutius o adel ERAS ER EE EACH e eee oe eS p ee det TC T TC 2 TC 3 24 TY 1 40 Stesring AM NUES Id oe ea Ee prx E REOR VE Amo nda wd e cR dae Rete id ze 120 Steering Gear Housing to Frame Bolt 2 2 1 eee eens 50 Steering Valve End Plug re eee ee 25 Steering Valve Body Attaching Bolts 0 0 0 et ee eee I ha 15 Steering Column Support Nut 0 0 0 0 00 ce e he aH ht 110 to 200 Steering Gear Shaft Cover Nul conste dee RLEEEE y ita End A fin caida dd idR Reda a RUE d dos 20 Steering Gear Shaft Adjusting Screw Lock Nut elles 50 POWER STEERING PUMP Pump Inner Pitted ooo a ee oh ene aa a rs ae hE ea ORO fi Eg Lees 30 Fump te Pump Bracket Bolis c cci es sao eis GEILE oko ee ERO SR ew a See eee eS 30 Reservoir to Pump Body Bolt ee ee Ee det Scb do K a ee ba td ere 10 15 PART 1 MANUAL STEERING The manual steering Fig 1 incorporates a flexible coupling Fig 2 which consists of a rubber fabric disc assembled between the two hubs installed be tween the steering gear worm shaft and th
35. e coils too tight or the wire will be dif ficult to remove CAUTION Use care when handling the rotor and shaft since the corners of the rotor are extremely sharp and must remain sharp for good pump opera tion The oil seal and bearing surfaces of the shaft must remain free of any nicks or burrs WIRE TOOL 63x678 SLIPPERS 4 Fig 64 Slippers Installed in Pump Rotor 63x679 Fig 65 Slippers and Spring Installed 11 Use an ordinary wood pencii with the point broken to install the new springs Enter the blunt tapered end of the pencil in the spring and snap the springs into the pockets in the rotor by turning tbe pencil clockwise Fig 63 Install the springs and slippers in one rotor slot at a time Remove the pen cil from the spring with a counter clockwise rotation Either end of the spring may be inserted into the rotor pocket NOTE Make sure the proper springs are installed The springs for the 96 pump small are not inter changeable with the springs for the 1 2 pump large 12 Install each slipper by sliding the slipper between the two springs and the wire tool so that the ends are flush with the rotor The notched portion of the slipper must be installed as shown in Figure LARGE PUMP 1 2 CU IN DISPLACEMENT 63x680 Fig 66 Slipper Retainer Washer Tool Dimensions 1 2 Pump 19 31 STEERING GEAR m REAR INSERT A situ ca ba ai WASHER a TOOL WIRE TOOL AE AE n
36. e pump Fig 50 Make sure all connections are tight and that the shut off valve is fully opened NOTE The pressure gauge must be installed between the pump and the shut off valve all connections must be tight and the shut off valve fully open 3 Remove the oil reservoir filler cap 4 Connect one lead of the tachometer to the distributor terminal of coil and the other to a good ground start the engine and operate at 500 rpm and fill the pump reservoir to the proper level 5 Expel all the air from the unit by turning the steering wheel to the full right turn and back to the full left turn several times and recheck oil level NOTE To assist in heating the pump oil slowly turn the pressure gauge valve towards the closed position until the gauge reads 400 psi and open the valve fully when the oil temperature reaches 150 degrees F 6 With the engine operating at 500 rpm and no steering effort applied the oil temperature should be between 150 and 170 degrees F measure with a thermometer in the reservoir the pressure gauge should show a pressure of less than 100 psi If the pressure is higher inspect the hoses and connections for kinks and obstructions or restrictions in the steering gear 7 Increase the engine speed to 1000 rpm then slowly close the gauge shut off valve With the gauge shut off valve fully closed the pump pressure should be as follows 1000 to 1100 psi for Models TC 1 TC 2 TC 3 1150 to 1300 psi f
37. e steering tube which provides alignment of the steering gear to the frame side rail and the vehicle body The steer ing gear chuck has a stub worm shaft which extends up a short distance above the gear housing The flexi ble coupling attaches to the worm shaft by a serrated connection and clamp bolt The worm shaft has a master serration that matches with the master serra tion in the lower hub of the flexible coupling The upper hub of the flexible coupling is integral with the steering tube The jacket tube is held in alignment in the vehicle body by the lower jacket clamp as sembly which attaches to the brake bracket and the instrument panel clamp The face of the steering gear housing is machined flat to position the gear fiush to the frame NOTE With an automatic transmission a 1 1 4 x 7 16 x 1 8 washer is added to the housing to the frame side rail bolt to compensate for the omission of the clutch torque rod mounting bracket STEERING GEAR 19 3 NUT es COVER Fr c GASKET dla RING 5 SCREW WASHER lt 5 SCREW A SHAFT AND ROLLER TOOTH CUP e WORM W SHAFT CAGE AND ROLLER HOUSING SEAL SEAL WASHER CY NUT 62 x 548A Fig 1 Steering Gear Disassembled View 19 4 STEERING GEAR SERVICE PROCEDURES 1 STEERING COLUMN Removal 1 Diseonnect the negative ground cable from the battery 2 Compress and turn the horn button turn countercloc
38. ee if the restrictor is installed properly if O K dirt may be restricting control valve movement or blocking the orifice or flow valve spring may be Fig 51 Flow Test Gauge Connections Typical weak If the return pressure is greater than 25 psi the flow valve may be stuck in the closed position 9 Decrease the engine speed to 500 rpm then slowly turn the pressure gauge shut off valve towards the closed position to obtain 850 psi on the pressure gauge at the pump discharge without fully closing the shut off valve CAUTION Do not close the valve completely With the above value registered on the pressure gauge the flow measuring gauge should show a mini mum pressure of 10 psi If the flow pressure reading is less than 10 psi in spect the flow valve operation for sticking if the valve is operating satisfactorily the pump is worn and should be replaced If the flow pressure reading is 10 psi or stene and the relief valve is operating properly inspect the steering gear for malfunction When removing the test equipment make sure the pressure and return hoses are reinstalled properly There should be no interference of the hoses with the components attached to the fender shield or the dash panel The return hose screen shouid be clean and re installed in the end of the return hose before rein stalling the return hose 15 POWER STEERING PUMP 1 Loosen the pump lower mounting bolt and re FLOW CONTROL VALVE
39. f the lever It must return easily to its center position when the worm torque is relieved 7 Install the valve body on the housing making sure that the valve lever enters the hole in the piston Fig 18 Be sure that the O ring seals are in place Tighten the valve mounting screws to 30 inch pounds torque 11 FINAL TEST ADJUSTMENTS AND SPECIFICATIONS 1 Remove the oil reservoir cover and fil the reservoir to the bottom of the filler neck opening 2 Connect the test hoses Tool C 3211 and Tool C 3318 with the proper adapters to the hydraulic pump on the vehicle with pressure gauge Tool C 3309B installed between the pump and the steering gear to register the pressures 3 Start the engine and operate at idle to bring the steering gear to normal operating temperature 4 Expel all the air from the unit by turning the worm shaft several times to the right and then to the left 5 Refill the reservoir before proceeding with the following test and adjustments on the bench a Tighten the steering valve body attaching screws to 7 foot pounds torque b With the gear shaft on center tighten the gear shaft adjusting screw until the backlash just disap pears Tighten 144 turns from this position and while holding the adjusting screw in this position tighten the lock nut Fig 46 NOTE This will bring the piston rack and the sec tor teeth in full alignment c Turn off the hydraulic power to the unit Oper
40. ferent result ing in a difference of reaction feel AIR NOZZLE 03 REACTION SEAL O RING JACKET TUBE SUPPORT 58x49 Fig 32 Removing the Reaction Seal from the Jacke Support FOOL SPANNER NUT i 58x44 Fig 33 Installing the Worm Shaft Upper Seal 2 Remove the large O ring from the groove in the jacket support 3 Remove the reaction seal from the groove in the face of the jacket support with air pressure di rected into the ferrule chamber Fig 32 4 Inspect all the grooves for burrs Make sure the passage from the ferrule chamber to the upper reaction chamber is unobstructed Assembly 1 Install the worm shaft upper oil seal using Tool C 3650 Fig 33 with the lip of the seal to ward the bearing 2 Lubricate and install the reaction seal in the groove in the face of the column jacket support with the flat side of the seal out Fig 34 Cylinder Head Disassembly 1 Remove the two O rings in the two outer grooves in the cylinder head 2 Remove the lower reaction O ring in the roove in the face of the cylinder head Apply air JACKET TUBE SUPPORT O RING REACTION RING 58x45 Fig 34 Installing the Reaction Seal into the Jacket Support O RINGS CYLINDER HEAD AiR NOZZLE REFER RERO MI Mira KI FERRULE REACTION O RING UH 58x46 Fig 35 Removing the Reaction Ring Seal from the Cylinder Head pressure in
41. g washer NOTE The needle bearing in the support consists of 33 needles originally retained in the support by heavy lubricant to facilitate assembly This lubricant how ever will have become dissolved in the hot hydraulic fluid with the unit in operation 3 To make sure the bearing needles do not drop out when removing the support place the arbor Tool C 3929 on the wormshaft and slide the support and bearing up on the arbor tool 4 Hold the worm shaft from turning then turn 19 16 STEERING GEAR STEERING GEAR HOUSING JACKET TUBE SUPPORT Fig 31 Removing the Worm Shaft Upper Seal the nut with sufficient force to release the staked portions from the knurled section and remove the nut NOTE Wire brush the knurled section to remove the chips then blow out the nut and worm shaft to remove any metal particles b Remove the upper thrust bearing race thin and the upper thrust bearing 6 Remove the center bearing race 7 Remove the lower thrust bearing and the lower thrust bearing race thick 8 Remove the lower reaction ring and the re action spring 9 Remove the cylinder head assembly NOTE The worm and piston assembly is furnished as a complete assembly only Column Jacket Support Disassembly 1 Remove the worm shaft upper seal with puller Tool C 3638 Fig 31 CAUTION Do not interchange the Imperial column jacket support with thar of any other models The machining on Imperial supports is dif
42. h a soap solution or rubber lubri cant This will make it easier to slide the column up or down for proper positioning in the vehicle when centering the steering shaft coupling 6 Apply wheel bearing lubricant to the nylon rings and lip of the jacket tube seal and position the seal cup and nylon rings on the jacket tube large diameter of the nylon rings butt and are retained by the recess caused by the seal lip Fig 5 7 Slide the seal onto the steering shaft and down against the coupling with the lip at the outside di ameter facing upward so the seal can be positioned on the lower end of the column jacket during assem bly 8 Slide the steering shaft into the column assem bly and install the horseshoe shaped lower snap ring in the lower groove on the steering shaft 9 Place the steering column upper bearing on the steering shaft BEAR ING NI SNAP RING INSTALLING 62x524 SLEEVE C 3879 R Fig 6 lnstalling Steering Column Upper Bearing Tool C 3879 19 6 STEERING GEAR 10 Position the wavy upper snap ring against the top of the bearing Place the bearing installing sleeve Tool C 3879 and the steering wheel retaining washer and nut on the top end of the steering shaft in that order Fig 6 NOTE Never press the bearing into position with a sleeve that exerts pressure against the outer race since this would damage the bearing Do not drive the bearing into place wi
43. idler or steer ing gear arm all seals should be closely inspected for wear or damage The tie rod ends are the per manently lubricated type If the tie rod or steering TIE ROD END ASSEMBLY A TIE ROD END COVER KNUCKLE ARM 62x72 Fig 16 Steering Linkage Disassembled View arm seals are damaged replace the assembly The tie rod seals and covers should be inspected at all oil change periods Damaged seals necessitate replacement of the tie rod end assembly The tie rod end seal covers are serviced separately CAUTION Removal of the tie rod ends from the steering knuckle arm or center link by methods other than using Tool C 3894 will damage the tie rod end seal necessitating replacement of the complete tie rod end assembly 1 Remove the tie rod ends from the steering knuckle arms using Tool C 3894 Use care not to damage the seals 2 Using Tool C 3894 remove the inner tie rod ends from the link 3 Remove the idler arm stud from the link us ing Tool C 3894 4 Remove the idler arm bolt from the cross member STEERING GEAR 19 11 5 Remove the steering gear arm stud from the link using Tool C 3894 Installation Replace all the tie rod and steering arm assemblies that are damaged worn or may have damaged seals 1 Insert the idler arm and bushing assembly into the bracket using care not to damage the bush ing Insert the bolt and tighten to 80 foot pounds torque 2 Insert the center link
44. il all the end play in the gear shaft is gone Rotate the wormshaft to one end of its travel and apply a torque wrench to rotate the wormshaft Tension should measure from 9 to 13 inch pounds The greatest tension should be felt as the wheel is rotated past the center position high point Adjust the torque load by turning the adjusting screw in or out as required 8 Install the lock nut and tighten while holding the adjusting screw 9 Fill the gear housing with SAE 90 gear lubri cant and test for leaks Installation In the Vehicle 1 Inspect the steering gear from center by ro tating the worm shaft from one end of its travel to the other while counting the number of turns Turn the worm shaft back one half of the full num ber of turns This is the exact center of travel 2 Locate the master spline in the outer row of serrations on the worm shaft Mark the master spline 3 Enter the steering gear into the engine com partment 4 Align the index mark on the outside of the fiexible coupling hub with the master spline on the steering worm shaft Fig 14 5 Slide the coupling on the worm shaft and in stall the gear housing to frame side rail attaching the bolts and nuts 6 Tighten the steering gear housing to frame bolts evenly to 50 foot pounds torque NOTE Tightening should be done by alternately tightening the rear and front mounting bolts grad ually so that the gear alignment is not disturbed FLEXIB
45. in the groove Install the spacer washer spring and tapered STEERING GEAR 19 23 COLUMN GROUND STRIP IF SO EQUIPPED SUPPORT INSULATOR GROUND STRIP Zur SO EQUIPPED Se er ee annate eryn fo ee S ee ye O A de le he lhe he ha VELUM ee S INSULATOR 60x19 rer PDC uem AR aae qos rr Fig 47 Jacket Tube installation spacer on top of the snap ring 4 On Chrysler and Imperial Models assemble the horn ground strap copper to the jacket tube support rubber insulator boot and instal this assembly into the lower end of the jacket tube Fig 47 5 Lubricate powder lubricant the end of the steering gear column jacket support and insulator boot to facilitate insulation and slide the jacket tube and insulator boot assembly down against the shoulder on the jacket tube support Tighten the clamp bolts securely NOTE There must be at least 14 inch clearance be tween the bottom face of the jacket tube clamp and the column support spanner nut to avoid metaf to metal contact 6 Install the jacket tube support bracket clamp at the instrument panel Tighten the clamp bolts to 15 foot pounds torque 7 Connect the directional signal wires and the horn wire at the connectors 8 On Imperial Models pry the steering column tube up with a wedge shaped tool or screw driver far enough to install the truarc ring in the column tube upper groove next to the bearing Make sure the
46. inak2 uns dec ote PRA eae ULM e DAS ca UP dux eet n 2 Needle Roller Bearings Warn Shaf Bediihij is x mai teet EE HERD RA RA In e Baa hee Ka ad RU ciega dot Tapered Roller High Point Wheels Straight Ahead Notch on Steering Column Tube Straight Up POWER STEERING Peligro aeu d so A aed a Seu ga diea oie dox o o ddr done eR rene a qoid diac Dots ce i ned 16 to Fluid Capacity of Hydraulic System 2 Qts Tope of f l iua dus Ra Ded e xt PROC USA OR dope a ca cd s ew a RR e dn ees Power Steering Fluid MoPar Part No 2084329 POWER STEERING PUMP Du ee eee ee ee er ere a ee ee D Mag Constant Displacement Maximum Pump Pressure TC 1 TC 2 TC 3 1000 to 1100 psi TY 1150 to 1300 psi Maximum Fluid Flow Rockies Biwi ach an Odo RECS A dre we auar Vea vad 2 gallons type of PUN PUE Power Steering Fluid MoPar Part No 2084329 19 2 STEERING GEAR TORQUE REFERENCE MANUAL STEERING Foot Pounds intermediate Steering Arm Pit Nut nini eR En he p REX PE Sud we ege ERU 50 Steering Geor fo Frame Bolt o ocior eee e ae e UR a UE ei ROCA R ere RR 50 Steering Geor Pitman Arm Nut coe hse E ERG Madre RN EROR RR QR NR cease 120 Steering Wheel Nut 0 02060 eR rr hn TC 1 TC 2 TC 3 24 TY 1 40 Steering Knuckle Tie Rod Clamp Bolt L tence eee es 15 Steering Knuckle Tie Rod End Ball Nuf 2 0 00 0002 c
47. kwise to release the button from the re tainer 3 Disconnect the horn wire at the horn blowing switch 4 Remove the three 3 screws and insulators at taching the horn ring and horn blowing switch to the steering column Remove the horn ring and switch 5 Loosen the steering wheel nut several turns and install the steering wheel puller Tool C 3428 and remove the steering wheel nut and steering wheel 6 Remove the screw attaching the directional switch lever to the directional switch and remove the lever 7 Disconnect the directional switch wiring at the steering column jacket tube below the instrument panel NOTE Attach a piece of string or fine wire to the directional switch wiring before removing the switch from the steering column When the switch is re moved leave the string or wire in the steering column jacket tube as an aid to replacement of the wiring 8 Remove the screws attaching the directional switch to the steering column and remove the switch from the top of the steering column 9 Remove the two bolts attaching the steering jacket tube clamp at the instrument panel and remove the clamp JP SEAL DISC COUPLING 63x687 Fig 2 Steering Gear and Flexible Coupling 10 Move the trim cap up on the steering jacket tube and release the floor carpet to expose the floor panel 11 Remove the screws attaching the dust pad to the floor panel and slide the dust pad up on the jacket tube 12 Remo
48. l View in the back pressure valve body Lubricate the back pressure valve piston and insert the nose end of the piston into the body bore Test for smooth oper ation Be sure the lower spring is not cocked 4 Install the pressure control valve spring on top of the valve piston Compress the spring and in stall the retaining pin 5 Install the two O rings and assemble the back pressure valve assembly to tbe control valve body Tighten the two attaching screws to 10 foot pounds torque 6 If the pressure inlet fitting has been removed replace the copper gasket and retighten the fitting to 30 foot pounds torque Gear Shaft Disassembly 1 Remove the gear shaft adjusting screw lock nut and remove the small O ring from the top of the cover and large O ring from the base of the cover Fig 38 NOTE The needle bearing in the cover consists of 51 needles originally retained in the cover by heavy Fig 39 Removing the Gear Shaft Oil Seal lubricant to facilitate assembly This lubricant how ever will have become dissolved in the hot hydraulic fluid with the vnit in operation CAUTION If for some reason the cover assembly must be removed from the gear shaft the 51 needles will fall out of the cover If any needles 51 become lost it will be necessary to replace the cover and bearing as an assembly Use wheel bearing lubri cant to retain the needle rollers in the cover when reassembling Assembly
49. lock ring seats in the groove Fig 24 IMPORTANT This lock ring places the upper column tube in the proper relation with the worm shaft coupling pin 9 Install the stationary plate bushings horn ring and attaching screws Connect the horn wire at the stationary plate and install the steering wheel ornament 10 Tighten the jacket tube to the instrument panel clamp screws Tighten the screws to 50 inch pounds torque Install the jacket tube cover 11 Position the directional switch install the attaching screws and the wire connections 19 24 STEERING GEAR 12 Install the directional switch lever 13 Install the steering wheel and steering wheel nut tighten the nut to 40 foot pounds torque Test the operation of the cancelling lever 14 Install the horn blowing switch mounting plate and the four attaching screws Fig 20 15 Install the horn blowing switch insulators and attaching screws Fig 19 Connect the horn wire 16 Install the horn blowing actuator the steer ing wheel cover and attaching screws 17 On Models TC 1 TC 2 TC 3 install the steer ing column and jacket tube as outlined in Part 1 Manual Steering Column Installation 18 Tighten the jacket tube to the instrument panel bracket screws Tighten the screws to 50 inch pounds torque 19 Install the steering column lower cover 20 Tighten the front upper and the lower gear housing to the frame attaching bolts to 24 foot pound
50. near the full turn in either direction attempt to return the unit to the center by applying a torque wrench at the steering gear cross shaft Hold the worm shaft until the cross shaft torque builds up to 50 foot pounds torque Release the worm shaft and maintain a constant steady pull on the cross shaft turning cross shaft slowly If the cross shaft torque does not drop to 25 foot pounds torque maximum as the piston passes through the center check for too much interior drag binding valve lever binding valve spool or cross shaft ad justment is too tight 6 With the unit under power but without any load the torque required to rotate the worm shaft through an included angle of 180 degrees 90 de grees either side of center shall be 6 to 9 inch pounds Disconnect the test equipment and the mount ing fixture and install the unit in the vehicle Steering Gear Installation on the Vehicle 1 Install the steering tube rubber insulator plastic insert upper steering tube and coupling pin and the horn ground strap 2 Enter the steering gear assembly into the engine compartment and through the opening in the floor panel Install the housing attaching bolts flat washers swivel washers and nuts but do not tight en The swivel washer permits alignment of the hous ing to the dash 3 On Imperial Models inspect the jacket bearing snap ring in the steering tube lower groove Install a new ring if the old ring will not fully seat
51. nect the test hose adapt er tube and pressure gauge Tool C 3309B with the proper adapters between the power steering pump and the hose disconnected from the pump Fig 51 NOTE The pressure gauge must be installed between the pump and the shut off valve all connections must be tight and the shut off valve fully open 3 Disconnect the return hose at the power steer ing pump NOTE Remove the return hose screen be sure screen is cleaned and reinstalled after the tests 4 Install the flow checking gauge set Tool C 3885 with the special hose between the power steer ing pump and the return hose disconnected from the pump Fig 51 CAUTION The fitting that has the restriction and the arrow on the tee connector must be towards the power steering pump Use passenger car orifice only 5 Remove the oil reservoir cover and fill the res ervoir to the proper level 6 Start the engine and operate at 500 engine rpm 7 Expel all the air from the unit by turning the steering wheel to the full right turn and back to the full left turn several times and recheck oil level 8 Increase the engine speed 1000 to 1200 rpm and no steering effort applied oil temperature be tween 150 and 170 degrees F Check the thermom eter in the reservoir the flow pressure gauge in the pump return line should read between 16 and 25 psi If correct measuring orifice is used for test and flow pressure gauge registers less than 16 psi inspect to s
52. new O ring on the pump body and install the reservoir and pump brackets E SS RUB SR STORE ADJUSTMENT MOUNTING i mL Suas p all 7 BRACK 61x257 mo RU Yu oce 278 5 mA Fig 71 Pump Bracket and Rubber Stop Power Steering Pump Installation in the Vehicle 1 Position the pump on the engine and install the attaching bolts 2 Install the drive beits and adjust See Para graph Belt Adjustment 3 Connect the pressure and return hoses 4 Fill the pump reservoir with power steering fluid MoPar Part No 2084329 9 Start the engine turn the steering wheel all the way to the left and back all the way to the right several times to expel the air from the system then turn off the ignition switch to stop the engine and recheck the fluid in the reservoir 19 BELT ADJUSTMENT 1 Losen the adjustment bracket to engine mount STEERING GEAR 19 33 ing bolts Fig 69 2 Install Tool C 3832 over the edge of the mount ing bracket as close as possible to the outer edge of bracket and insert torque wrench drive in square hole of tool Fig 70 3 Tighten the pump belt until you get a reading of 45 foot pounds on the torque wrench 4 While holding the tension with torque wrench tighten the bracket mounting bolt nuts enough to hold the adjustment then use torque wrench to 30 foot pounds torque When the belt is properly adjusted and normal pump pressures are developed the pump mounting
53. ng column jacket bracket Be sure the jacket tube clamp bolt is securely tightened 6 Slide the dust pad down into position on the dash panel and install the attaching screws 7 Position the floor carpet under the dust pad and position the trim cap 8 Attach the string or wire that was left in the steering column jacket tube during removal to the directional switch wiring and carefully pull the string or wire down through the column jacket tube until the directional switch wires can be connected Posi tion the directional switch in the steering column jacket tube and install the attaching screws and con nect all wire connections 9 Install the directional switch lever 10 Install the steering wheel and the steering wheel nut tighten to 24 foot pounds torque Test the operation of the cancelling lever 11 Install the horn blowing switch horn ring insulators and attaching screws Connect the horn wire 7 12 Install the horn button by compressing and turning 4 turn clockwise to lock the horn button on the retainer 13 Connect the je e cable at the battery nega tive terminal 14 Inspect the steering gear shaft for alignment in the steering column seal and steering jacket alignment as outlined under Steering Gear Align ment 15 Measure the up or down deflection of the flexible disc as follows If the deflection exceeds X inch the column jacket should be moved up or down to where the deflection of
54. on ring with the cylinder head ferrule through the hole in the spring 10 Install the reaction ring without flange in side the upper reaction ring 11 Lubricate the ferrule O ring with petro latum and install it in the groove on the cylinder ferrule 12 Carefully install the jacket support over the worm shaft engaging the cylinder head ferrule and the O ring and making sure the reaction rings enter the circular groove in the jacket support ADJUSTING NUT CENTER THRUST BEARING RACE CYLINDER HEAD PISTON weed I A Jr s Vd i k I p am AR a9 kal I EM __ id WORM SHAFT BEARING RACE 59x141 Fig 45 Staking the Worm Shaft Bearing Adjusting Nut 19 22 STEERING GEAR CAUTION Form a 0015 inch feeler gauge into a coil and insert with the jacket support to protect the lip of the seal when installing over the worm shaft serrations 13 Align the parts on the power train so that the valve lever hole in the center bearing spacer assembly is 90 degrees counter clockwise from the piston rack teeth and hold all the parts together 10 STEERING GEAR Assembly 1 With the steering gear housing in the holding fixture Tool C 3323 in approximate car installed posi tion lubricate the bore of the housing with petro Jatum and carefully install the power train assembly Fig 18 with the center bearing spacer valve lever hole in UP position to line up with the control valve lever
55. or Models TY 1 CAUTION Do not close the valve for more than a few seconds as this would abnormally increase the ail temperature and cause undue oil pump wear a If the pressure increases to more than 1100 psi for the Chrysler Models and 1300 psi for the Im perial Models the relief valve 1s faulty or the pump is equipped with the wrong relief valve b If the pressure is less than 1000 psi for the Chrysler Models and 1150 psi for the Imperial Mod els the relief valve is faulty Repiace the relief valve with the correct relief valve known to be in working order and repeat the test in step 7 If the pressures 19 26 STEERING GEAR are still below specifications disassemble the pump and test the flow control valve for evidence of foul ing or slipper spring breakage c With the gauge shut off valve fully open oper ate steering unit through another cycle this time holding the unit at the extreme travel in each direc tion while watching the oil pressure gauge The gauge reading should be equal in each direction If not it indicates excessive internal leakage in the steering gear unit Do not hold the worm shaft at either extreme position for more than a few seconds d If the pressures are within the ranges specified make a flow test as outlined in Pump Flow Test 14 PUMP FLOW TEST 1 Inspect the pump belt tension See Cooling System 2 Disconnect the pump pressure hose at the power steering pump and con
56. r with the lip of seal toward the housing Fig 8 3 Drive the oil seal into the housing bore with Tool C 3821 Fig 9 Fig 10O Removing the Gear Shaft Oil Seal 19 8 STEERING GEAR Gear Shaft Oil Seal Replacement Removal Fig 10 1 Replace the gear shaft oil seal with Tool C 3350 gear shaft oil seal removing and installing tool set as follows 2 Slide the threaded portion of the adapter SP 3056 over the end of the gear shaft and install the threaded nut section of the tool on the gear shaft 3 Maintain the pressure on the adapter SP 3056 with the nut of tool while turning the adapter SP 3056 forcing it into the seal until it engages the metal lip of the seal 4 Slide the retainer of Tool C 3350 over the adapter engage the grooves in the adapter and the tool nut with the two half rings of the tool set and slide the retainer down to hold the half rings in posi tion 5 Turning the puller nut counter clockwise will pull the oil seal from the housing Installation Fig 11 1 Place the seal on the seal protector sleeve Tool SP 1601 and install the sleeve over the splines on the gear shaft lip of seal toward housing 2 Place the adapter Tool SP 1934 over the pro tector sleeve and against the seal 3 Thread the tool nut on the threaded end of the gear shaft and turn the tool nut until the shoulder of the adapter tool contacts the housing If the gear shaft bearings have been removed
57. rn hose connections and fittings c Reservoir to pump body O ring or mounting screws d Pump shaft oil seal Correction a Replace relief valve and perform Pump Pressure Test b Replace relief valve and perform Pump Pressure Test a See Fluid Level b Tighten all fittings check hose for deterioration replace any faulty hoses If the discharge fitting is leaking See Power Steering Pump Discharge Fitting Ferrule Replacement c Replace the reservoir O ring and tighten reservoir mounting Screws d Replace oil seal
58. rotor are in contact with the eccen ric inside diameter of the housing As a rotor revolves the slippers force the oil from the inlet side of the pump to the flow control valve Orifices in the valve permit a flow of approximately two gallons per min ute to the gear before the valve moves to the right to allow the excess to flow back to the inlet side of the pump Maximum pressure in the system is limited by the pressure relief valve The valve opens into the reservoir when the pressure exceeds the maximum pressure specified 12 FLUID LEVEL 1 Start the engine turn the steering wheel back and forth several times to expel the air from the sys tem then shut off the engine 2 Remove the filler cap and visually inspect the oil level in the reservoir Engine Cold Oil lever should be at the bottom of filler neck Engine Hot 0il level should be one half way up in fill neck If necessary add only MoPar Power Steering Fluid Part No 2084329 to the required level Do not overfill 13 PRESSURE TEST 1 Measure the pump belt tension See Cooling System 2 Disconnect the pump to the steering gear pressure hose at the power steering pump Connect HOSE ADAPTER NEM Z STA Fig 50 Pressure Test Typical the test hose Tool C 3388 with the proper adapter between the power steering pump and pressure gauge Tool C 3309B with a shut off valve between the pressure gauge and the pressure hose that you dis connected from th
59. rs and remove the horn blowing switch Fig 19 10 Remove the four screws and remove the horn blowing ring mounting plate Fig 20 11 Loosen the steering wheel nut several turns and install the steering wheel puller Tool C 3428 Fig 21 and remove the steering wheel nut and the steering wheel 12 Remove the directional switch lever Fig 22 13 Remove the steering column lower cover 14 Remove the two screws and disconnect the switch wires at the connection and remove the direc tional switch and wires Fig 23 15 Remove the retainer snap ring Fig 24 from the groove in the steering tube at the top of the bearing using pliers Tool C 3229 16 Remove tbe jacket tube shield to allow ac cess to the column tube clamp and remove the screws attaching the steering jacket tube clamp at the in strument panel and remove the clamp 17 Raise the carpet to expose the floor panel Move the rubber grommet up on the jacket column 18 Remove the screws attaching the rubber dust boot at the firewall On TY 1 Models remove the floor inspection panel STEERING GEAR 19 13 Fig 22 Directional Switch and Lever Steering Wheel Removed 19 On Chrysler and Imperial Models loosen the jacket tube clamp at the steering gear housing 20 Remove the cotter key and nut at the cover link and disconnect the link from the arm 21 Remove the arm nut and washer at the steering gear shaft 22 Slide Tool C 3646 up
60. rt the engine and run at idle speed With hydraulic power to the steering gear unit and with the gear shaft on center plus or minus 2 degrees readjust the gear shaft backlash This will require loosening the adjusting screw until the backlash is evident Retighten the adjusting screw until the backlash just disappears Continue to tighten to V5 turn from this position and tighten the lock nut 50 foot pounds torque to maintain this setting 8 POWER STEERING GEAR UNIT Removal 1 Disconnect the battery cable at the battery negative post 2 On Models TC 1 TC 2 TC 8 perform steps 1 19 12 STEERING GEAR GIL OUT BACK PRESSURE VALVE LEFT TURN POWER O CHAMBER POWER PISTON RIGHT TURN CHAMBER aum STEERING GEAR CROSS SHAFT SUL OIL IN VALVE BODY t SPOOL VALVE PIVOT LEVER CENTER THRUST BEARING RACE STEERING COLUMN CONNECTION COLUMN JACKET SUPPORT WORM SHAFT SALANCING RING LEFT TURN REACTION RING RIGHT TURN REACTION RING CYLINDER HEAD WORM SHAFT RECIRCULATING BALL CIRCUITS 59x140 A Fig 18 Steering Gear Sectional View through 11 under Manual Steering Column Re moval 7 On Models TY 1 remove the two serews from the underside of the steering wheel and remove the horn blowing actuator and the steering wheel cover 8 Disconnect the horn wire at the horn blowing switch 9 Remove the four screws and insulato
61. s sembly of Power Train 5 See Steering Gear Removal Disassembly and Inspection re place parts as necessary See Dis assembly and Assembly of Power Train 6 Remove the steering gear and repair as necessary 7 Remove the steering gear dis assemble completely clean in a clean solvent inspect and make repairs as necessary 8 Replace the worm and piston as sembly See Steering Gear Re moval Disassembly Inspection and Reassembly Inflate the tires to recommended pressures See Wheels and Tires 19 36 STEERING GEAR SERVICE DIAGNOSIS Continved POWER STEERING Condition Possible Cause Correction 27 Excessive Steering Wheel Free Play Lack of Assist l One Direction Both Directions Temporary increases in Effort When Turning Steering Wheel to the Right or Left b Improper wheel alignment c Valve body out of adjustment d Valve lever damaged e Column support spanner nut loose a Improper gear shaft adjustment b Column support spanner nut loose c Improper worm thrust bearing adjustment d Coupling loose on the worm shaft a Oil leaking past worm shaft oil seal ring b Broken or worn ring on worm piston c Piston end plug loose d Reaction seal missing a Pump belt slipping b Faulty pump pump output low c Broken or worn ring on worm piston d Piston end plug loose e Internal
62. s and towards the fender shield Slide the steering gear towards the rear of the vehicle and at the same time raise the lower end of the gear to remove the gear at the engine compartment Disassembly Fig 18 NOTE Prior to disassembly clean the gear assembly thoroughly in a suitable solvent and install the unit STEERING GEAR 58x231 Fig 25 Removing the Steering Gear Arm COLUMN SUPPORT GROUND SIRIP IF SO EQUIPPED SEAL IF SO EQUIPPED INSULATOR GROUND STRIP una eee cee eee et Serre a neta ete dra aima raa di INSERT mm pna PLASTIC 2 Mis NSNNNS 2 SS E mo i P VE STEERING TUBE F INSULATOR 60x19 Fig 26 Jacket Tube and Column Tube Cross Section in the holding fixture Tool C 3323 When disassembling each part should be placed in a suitable solvent washed then dried by dry com pressed air Careful handling of the parts must be exercised to avoid the occurrence of nicks and burrs Crocus cloth may be used to remove small nicks or burrs provided it is used carefully When used on the steering gear valve use extreme care not to round off the sharp edge portions of the two lands located between the valve drilled holes The sharp edge portion of these two lands is vitally important to this type of valve Remove and discard all O seal rings and seals Use new ones lubricated with petrolatum when re assembling 1 Drain the steering gear through the pressure
63. s pressed into place by reinstalling the high pressure hose and tight ening the flare nut to 24 foot pounds torque Figure 57 is a cutaway view to show the ferrule properly seated in the housing CAUTION Be sure that the ferrule is centered in the housing bore before installing the high pressure hose 17 FLOW CONTROL VALVE Removal 1 With the pump reservoir removed remove one of the flow control valve end plug retaining rings and end plug Fig 58 Fig SB Removing Flow Control Valve Retaining Ring 2 Depress the control valve against spring pres sure and allow it to spring back The valve should pop out of the bore to a point where it can be re moved If the valve should stick do not force it but repeat the spring back procedure several times Gum deposits wil cause the control valve to stick in one position and it will be necessary to break the valve free by light tapping and repeat operation 2 NOTE Inspect the flow control valve and valve bore If the valve or valve bore in pump body are badly scored replace the pump assembly less pulley and reservoir If the control valve and bore were fouled by gum ming foreign material or burrs the valve and valve bore should be thoroughly cleaned and flushed and reassembled Installation 1 Install the control valve spring seating the spring in the spring socket 2 Remove any burrs with a fine hone or crocus cloth but Do Not round the valve Iand corners 8
64. s torque 21 Install a wedge over the rear bolt Fig 48 between the housing and the frame so that the ta pered surfaces match wedge lightly into place and tighten the three attaching bolts to 50 foot pounds torque LOCKW ASHER BOLT hee NUT 77 X EXP A 7 7 R STEERING GEAR HOUSING SS ZUM i BE SS WEDGE FLAT WASHER SPHERICAL SPACER FRAME RAIL i I aa FLAT WASHER gt f 14 60x16 Fig 48 Steering Gear Mounting 22 Install the steering gear arm washer and nut Tighten to 120 foot pounds torque 23 Install the steering center link nut and cot ter pin 24 Connect the pressure and the return hoses 25 Install the hydraulic brake line at the master cylinder and brake tee Bleed the brake as necessary 26 Refill the reservoir Expel all the air from the system by turning the steering wheel several times to the right and left 27 Connect the battery cable at the battery neg ative post ROTOR RELIEF VALV FLOW CONTROL PLUG SNAP RING OH SEAL METERING INSERT aay Ts M o KE N NNN SPRINGS 8 Sa ES DAN TES SLIPPERS 4 FLOW CONTROL OIL SEAL SNAP RING FLOW CONTROL PLUG SS i 60x7 51A Fig 49 Slipper Type Power Steering Pump STEERING GEAR 19 25 PART 3 POWER STEERING PUMP The power steering pump is a belt driven constant displacement pump In operation Fig 49 the spring loaded slippers in the pump
65. th a hammer since damage to the bearing and steering shaft coupling will occur 11 Turn the steering wheel retaining nut to exert pressure on the installing sleeve upper snap ring and bearing pressing the bearing down onto the knurled section of the steering tube and against the lower snap ring NOTE The steering column upper bearing has ap proximately 001 interference fit at the knurled sec tion of the steering shaft 12 Exert sufficient pressure against the upper snap ring to flatten it against the bearing so it can enter the groove in the steering tube Be sure the snap ring is firmly seated in the groove 13 Place the bearing insulator over the bearing column upper bearing and position the bearing and insulator in the counterbore provided in the bearing housing Installation In the Vehicle 1 Enter the jacket tube and steering column shaft assembly through the dash panel from the driv er s side and index the lower coupling of the steering gear shaft with the steering gear worm shaft 2 Index the master groove of the steering gear worm shaft with the filed notch on the lower cou pling Tap the coupling down over the worm shaft splines 3 Install and tighten the coupling clamp bolt securely 4 Align the jacket tube at the instrument panel and install the jacket tube clamp and attaching screws Tighten the screws finger tight 5 Install the two nuts attaching the lower jacket tube clamp to the steeri
66. to the oil hole located in the groove be tween the two OQ ring grooves Fig 35 3 Inspect the worm shaft seal in the cylinder head counterbore for possible damage replace the eylinder head seal if necessary Fig 36 Assembly 1 Inspect the oil passage in the ferrule for ob struction and cylinder head lands for burrs then lubricate the two large O rings and install in the grooves on the cylinder head 2 Install the cylinder head oil seal back up ring and retainer if removed Make sure the retainer is seated in the groove 3 Install the lower reaction seal in the cylinder head groove NOTE The small O ring for the ferrule groove should be installed after the worm shaft bearing preload has been established otherwise the small NN FERRULE 3 CYLINDER HEAD MAT OIL SEAL FERRULE O RING ta pai s m LI RETAINER O RING 58x47 Fig 36 Removing the Cylinder Head Seal STEERING GEAR 19 17 CONTROL g SCREW O RINGS VALVE fc JA Q RINGS BODY f t O RING o PIN SPRING SPRING e wu STEERING ay VALVE BODY PISTON Ae N iid pirring CASKET lt SCREW G MER z g 58x48 A END PLUG Fig 37 Contro Valve Disassembled View O ring will be damaged by the reaction springs and the center bearing spacer Steering Valve Assembly Disassembly Fig 37 1 Remove the two screws attaching the pres sure control valve body to the steering valve bo
67. ve the two nuts holding the lower jacket tube clamp to the steering column jacket bracket 13 Remove the clamp bolt from the steering col umn shaft lower coupling 14 Carefully lift the steering column toward the dash tapping the lower coupling lightly with a mallet until it is free of the worm shaft splines 15 Slide the steering gear jacket tube assembly rearward and remove the complete assembly through the driver s compartment Steering Column Disassembly 1 Remove the turn signal lever retaining screw and remove the lever NOTE Disassemble repair and assemble the steering column assembly on a clean padded bench to protect the finish on the col umn jacket and related parts 2 Remove the 3 recessed head switch retaining screws as shown in Figure 3 and pull the turn signal switch and switch plate up and out feeding the wires and connectors through the steering column jacket 3 Disengage the column jacket lower seal from the lip on the jacket and slide the seal down toward the coupling 4 Exert an upward force on the steering shaft SWITCH RETAINING CREWS 3 BEARING HOUSING BOLT 2 a cx Fig 3 View of Steering Column Upper End BEARING PULLER STEERING SHAFT BEARING T s V a d a t T 4 i a Mirt gt oat EC I E y Nx Fig 4 Removing Steering Shaft Bearing 62x455 to force the steering column jacket upper bearing and
68. ws behind the bearing hold the center screw while turning the puller nut to pull the lower outer needle bearing out of the bousing b Use puller Too C 3332 to remove the upper inner needle bearing Assembly 1 Install the gear shaft bearings into the hous ing with driver Tool C 3333 lettered end of the bearings against the driver tool Drive the bearings to W inch below the edge of the counterbore 2 Install the gear shaft oil seal into the housing lip of seal toward needle bearing with adapter SP 3052 and Tool C 3350 as follows a Place the long lip of the adapter against the seal and thread the tool nut on the threaded end of the gear shaft Fig 41 b Turn the tool nut on the gear shaft until the shoulder of the adapter tool contacts the housing c Remove the tools and install the oil seal back up washer and snap ring CAUTION Make sure the snap ring is properly seated in the groove in the housing Fig 38 d Install the cross shaft outer seal 9 POWER TRAIN Assembly If the power piston ring was removed at disassem bly inspect the condition of the rubber sealing ring and install a new cast iron ring with Tool C 3676 Piston Ring Remover and Installer as follows a Position Tool C 3676 in the vise Fig 43 b Slide a new piston ring into place in the piston groove c Place the piston and ring assembly in Tool C 3676 with the lower part of the piston and the ring resting on the land of tool

STEERING GEAR (PUMPS, STEERING GEAR ARM

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