301-20 SAGINAW STEERING GEAR DIVISION orsensPOWER STEERING GEARS 301-21 1. REMOVE AND INSTALL PITMAN SHAFT SEALS IN CAR REMOVE INSTALL 1. Clean exposed ena 1. Install parts as shown otpitmen shaft and nd ofhousing after removing pitman arm HOUSING ASSEMBLY Inspecttor burs 2. Remove retaining fing with snap ae fing pliers e424 aa 3. Start engine and is turn wheels fly SEAL (SINGLE LIP) tothe lettto le. forceseals and OT WASHER qo SEAL (OOUBLE LIP} Oe WASHER Sl RETAINING RING OS PrTman an Gea LOCK WASHER B-— NuT-Torgue to 250 Newton Metres 5 (180 Ft. Lbs.) 4. Turn off engine. 5. Inspect housing and shatt PITMAN SHAFT Inspect seal surface for roughness ang pitting i i i i Puller | J-29107 | Formerly! -0632 r i 1 I IV 1 i L Remove Pitman Arm install Seals 3. REMOVE AND INSTALL HOUSING END PLUG REMOVE INSTALL 1. Remove parts 1. Install parts as shown, as shown, Open end ot retaining ‘ing to be approx. 25 mm (Tinh) trom access hole. Retaining ring access hole (Use Punch} HOUSING END PLUG (0 RING SEAL, HOUSING END PLUG RETAINING RING 2. REMOVE AND INSTALL PITMAN SHAFT AND SIDE COVER REMOVE INSTALL 1. Itpitman shatt and 1. removed, install side cover are to be gasket seal by separated, remove Bending tabs around preload adjuster nut cover edges, 2. Rotate stub shatt to 2. Install parts center gear. then as shown, Femove partsasshown. oe Coven BOLTS Torque to 60 Newton Metres Gort us Separate pitman shaft and gasket seal from side Cover if required STUB SHAFT HOUSING ASSEMBLY 4, REMOVE AND INSTALL RACK PISTON REMOVE INSTALL 1, Remove parts as shown, 1. Install parts as shown When instaling cack care should be taken not to cut telion seal, rack piston seal compressor 7576 oF J-8947 may be used to compress seal Insert ball retainer J-21552 Hold tool tightly ‘against worm while turning stub shaft ‘counter-ciockwise. The rack-piston will be forced Must be removed ‘onto the tool. Remove the before removing rack-piston and ball rack retainer trom the gear housing toget RACK PISTON PLUG. orsess301-22 SAGINAW STEERING GEAR DIVISION 5. REMOVE AND INSTALL ADJUSTER PLUG ASSEMBLY REMOVE INSTALL 1, Loosen lock nut 1, Install parts Use punch against as shown, edge of slots. 2, Remove adjuster plug using spanner wrench J-7624 ADUUSTER PLUG Lock NuT SS NOTICE: wnen instating adjuster plug care should be taken not 10 cul seals 6. DISASSEMBLE AND ASSEMBLE ADJUSTER PLUG ASSEMBLY DISASSEMBLE ASSEMBLE 1. Disassemble parts 1. Assemble parts asshown, asshown, goF |ETAINING RING ‘STUB SHAFT DusT SEAL L. stue sHarr Seat NEEDLE BEARING ADJUSTER PLUG (O° RING SEAL. UPPER BEARING RACE (LARGE) UPPER THRUST BEARING UPPER BEARING RACE (SMALL) ‘THRUST BEARING SPACER S BEARING RETAINER: {RETAINER % 6 9 t Screwdriver Pry bearing retainer atraised area a] Riemove bearing retainer OT | lyomervzo2 | ! I Driver 7079-2 | Instalersasees. | = 1 ‘Also use for seal | ! i | installation after | i 1 \_\eeating sin pace Drive bearing | | | arose || trom adjuster i ! | <— Bearing with Beatin ‘aenifeation ' femore | |B tomar” | \ ieee || ' ‘/ l | 'Lrowsrenrwue | ILapusterpLus LL 1 wee Remove bearing and seals Install bearing and seals. 7. REMOVE AND INSTALL BEARING, WORM, AND VALVE ASSEMBLY REMOVE INSTALL 1. Grasp stub shaft and 1, Install parts as femovevaiveandworm shown. assembly as aunit. ‘Separate the valve from the worm. Note how the pin in the worm fits the slot inthe valve THRUST BEARING AND RACES. ‘VALVE ASSEMBLY WORM ASSEMBLY NOTICE: when reassembling ‘gear make sure angle of thrust races are as shown, 8. DISASSEMBLE AND ASSEMBLE VALVE DISASSEMBLE ASSEMBLE 1) Disassemble parts 1. Assemble parts as shown as shown, VALVE BODY “0” RING VALVE BODY VALVE SPOOL S—~_ ‘STUB SHAFT) q V 0 ALVE BODY a” \ RING (tellon) Shalt cap ‘SPOOL TO BODY "0" RING ' B. Remove and install stub shatt A. Loosen shatt cap } Tap lightly on wood block Pinon shaft and hole in ‘spool! (Disengage to remove) ©. Remove andinstall spool! | 0. Engage stub shatt Rotate while removing or snstalting I Hp | e\ LI \ i { I 6 | Lubricate spool and body lotch must fully engage with power steering fluid. pin and.cap must seat ‘against shoulder.POWER STEERING GEARS 301-23 9. DISASSEMBLE AND ASSEMBLE RACK PISTON DISASSEMBLE ASSEMBLE 1, Disassemble parts 1. Assemble parts as shown, as shown, 2. Clean and inspect all parts tor excessive wear NOTICE: The black balls are smaller than the silver balls. The black and silver balls must be installed alternately into the rack-piston and return guide to maintain rack piston to worm gear prelead. TEFLON SEAL AND "0" RING— It replaced lubricate new seal and"O" ring with power steering lui Turn worm until worm groove is aligned with the lower ball return guide hole. WORM-Slide all tre way into the rack-piston. Lubricate balls with ower steering fui. Install balls. through ball return guide hole, while rotating worm counterclockwise Before assembling rack inhousing, ball retainer 421552 must be inserted into rack to allow removal of worm GUIDE—alternately install remainder of, balls and retain with grease at each end ot guide. he] —cLame SCREW-Tighten 105 Newton Metres (4FtLbs) 10. REMOVE AND INSTALL PITMAN SHAFT SEALS AND BEARING REMOVE. INSTALL 1. Cleanendot 1. Coa seal ip and vashor aco ovsing thoroughly in ankydauscaloum gese Loprevent trom 2 gta partsas shown uvomely careful not eso herousing wore HousING ASSEMBLY Inspe! fr burs. 2. Remove retaining ring with snapring pliers, 4248, 3, Using serew driver, els ane washers q| Pore PITMAN SHAFT SEAL (SINGLE LIP) KOS PrTMAN SHAFT SEAL ED joousue ci) SEAL BACK UP WASHER NEEOLE BEARING Remove only ifit Reeds replacing 4 Bearing | see7e 1 t | I i I i i i J Le Removing bearing _ ee a i | — installer raogs Installer 58219 522407 \ When tool bottoms on housing bearing is 1 1 1 i 1 i ' i 1 1 I i 1 i i 1 i i | 1 | tly instated 1 1 1 1 1 1 1 1 1 I I i I Instaier | i 1 1 i ' 1 i ' i a 4 Li. Install Pitman shaft bearing i I ! | i 1 1 1 i ' I I I | i I I | i i i t 1 J Install Pitman shatt seals o1sees301-24 SAGINAW STEERING GEAR DIVISION 11, REMOVE AND INSTALL CHECK VALVE REMOVE 1, Remove parts as shown. INSTALL 1. Install parts as shown, with small screwdriver. pry check valve from nousing (care snouts ve takan not to damage threads when prying ‘on edge of housing, Using @ piece of % tubing, 4 inches long, caretuly drive the check. valve into the housing Install check valve 12. ADJUST THRUST BEARING PRELOAD A. Betore adjusting bearing preload rotate the stub shaft back and forth to drain al oil from gear B. Usingspannerwrench | ¢. 4-726, tighten adjuster plug unti thrust Dearing is fly bottomed, 27 Newton Metres (22 Fi. Lbs.) ae Measure back counterclockwise 13mm ('") and place a Mark housing and face of adjuster Turn adjuster counterclockwise until mark on face of adjuster lines up with second mark on housing Using punch in notch | tighten tock nut securely | Hold adjuster plug to | maintain alignment of | the marks, 13, PITMAN SHAFT “OVER-CENTER” SECTOR ADJUSTMENT When gear is on center, flat on stub shalt is normally on same side as, ‘and parallel with, side cover, ‘The block tooth on the Pitman, shattis in ine with the ‘over-center preload adjuster. —’ B. Back off preload adjuster | C. Turn adjuster in until until it stops, then turn torque to turn stub shat itin one full turn (610 10 in. Lbs) ‘more than reading #1 With gear at centar of travel, check torque to turn stub shatt (reading #1) Torque adjuster lock rut to 27 Newton Metres (20 Ft'Lbs.) Prevent adjuster screw from turning while torqueing lock nut is 06 to 1.2 Newton Metres orsees,POWER STEERING GEARS RECOMMENDED TORQUE SPECIFICATIONS Gear to Frame Bolts High Pressure Line Fitting (At Gear) il Return Line Fitting (At Gea) Adjusting Screw Locknut Side Cover Bolts Adjuster Plug Locknut Coupling Flange Nuts Return Guide Clamp Screws Raack-Piston Plug Pitman Shaft Nut Coupling Flange Bot SPECIAL 4245 — Snap Ring Pliers 46217 — Connector Seat Installer J-6219 — Pilman Shalt Seal installer J-6278_ — Pitman Shatt Bearing Remover J-7079-2 — Handle J-7576 — Rack Piston Seal Compressor (78 mm 3%" | Piston Bore) ¥-7624— Spanner Wrench 1-754 — 0-5 Newton-metre Torque Wrench (0-25 inch-pounds} NEWTON METRES 95 35 35 27 6 108 27 5 102 244 41 TOOLS 8058 — 092 — 8524-1 — 8524-2 — 8947 21982 — 22407 — -28323 29107 — FOOT-POUNDS 70 25 25 20 45 80 20 4 75 180 30 0-125 Newton-metre Torque Wrench (0-50 foot-pounds) Handle Adjuster Plug Bearing Installer Adjuster Plug Bearing Remover Rack Piston Seal Compressor (70 mm |2%"| Piston Bore) Ball Retainer Pitman Shaft Bearing Installer Power Steering Analyzer Pitman Arm Puller 301-25 orsees