HOUSING END PLUG INSTALLATION.

(4) Insert rack-piston arbor in end of worm

6-159. HOUSING END PLUG REMOVAL. Proceed

(71). Rotate stub shaft to left turn, which will force rack-

as follows:

piston ball nut (77) onto arbor, and remove rack-piston

(1) Rotate end plug retainer ring (56) so that

ball nut from gear housing, taking card to keep arbor in

one end of the ring is over the hole in the housing.

place in the rack-piston nut or the balls will fall out. If

Spring one end of ring with punch to allow screwdriver

rack-piston ball nut is being removed to replace the

to be inserted to lift ring out.

piston ring (72) and back-up

packing

(73),

(2) Rotate stub shaft (88) with 3/4 inch box

reassemble without further disassembly.

end or socket wrench to left turn corner position and

(5) Remove valve assembly as outlined in

force end plug (55) out of housing.

CAUTION

paragraph 6-149.

(6) Remove worm, lower thrust bearing and

Do not rotate further than necessary, or the balls

races.

from the rack and worm assembly will fall off the

end of the worm.

6-164. RACK-PISTON AND WORM ASSEMBLY AND

GEAR HOUSING DISASSEMBLY. Proceed as follows:

(3) Remove and discard housing end plug

(1) Cut piston ring (72) and packing (73)

packing (57).

back-up seal, remove from rack-piston ball nut (77) and

discard.

6-160. HOUSING END PLUG INSTALLATION.

(2) Remove screws and lock washers (75)

Proceed as follows:

from rack-piston nut with screwdriver.

(1) Lubricate new housing end plug packing

(3) Remove ball return guide clamp (74).

(57) with SAE 10 engine oil, and install in gear housing

(4) Place the assembly on a clean cloth and

(97).

remove ball return guides (76) and arbor. Make sure all

(2) Insert housing end plug (55) into gear

of the balls (78) are caught on the cloth.

housing and seat against packing.

(3) Install end plug retainer ring (56) with

6-165. RACK-PISTON AND WORM ASSEMBLY AND

fingers. Install one end of ring and work ring into groove

GEAR HOUSING INSPECTION. Proceed as follows:

until seated. Slight tapping may be required to securely

(1) Inspect housing assembly. If bore is

bottom retainer ring in gear housing.

badly scored or worn, replace housing. If connectors

(95 and 96) are badly brindled or scored, replace them.

6-161. RACK-PISTON END PLUG REMOVAL.

To remove connectors, tap threads in connectors, using

Proceed as follows:

a 5/16-18 tap. Thread a bolt with nut and flat washer

(1) Remove housing end plug as outlined in

attached into tapped hole. To pull connector, hold bolt

paragraph 6-159.

from rotating while turning nut off bolt. This will pull

(2) Remove rack-piston end plug (58) by

connector from gear housing. Discard connectors.

inserting a 1/2 inch drive socket extension into the

(2) Inspect ball plug (93) in housing. If it is

square hole in the plug and turning counterclockwise.

leaking or raised above housing surface, drive it in flush,

to 1/16 inch below the surface. Tighten ball by staking

6-162. RACK PISTON END PLUG INSTALLATION.

the housing. If leakage cannot be stopped, housing

Proceed as follows:

must be replaced.

(1) Turn plug into rack-piston and tighten to

(3) Inspect all seal surfaces and retaining ring

50 to 100 foot pounds.

grooves for defects. If any defects are found, housing

(2) Install housing end plug as outlined In

must be replaced.

paragraph 6-160.

(4) At initial assembly, the rack-piston nut,

worm and balls are selected to obtain a preload of I to 4

6-163. RACK-PISTON AND WORM ASSEMBLY AND

inch pounds measured on center through an angle of 90

GEAR HOUSING ASSEMBLY REMOVAL. Proceed as

degrees. This preload may drop during service, without

follows:

having any noticeable effect on steering.

Upon

(1) Remove housing end plug as outlined in

complaint of loose or hard steering, thrust bearing

paragraph 6-159.

adjustment and overcenter adjustment will correct the

(2) Remove rack-piston end plug as outlined

problem if it lies in the steering gear adjustments. If

in paragraph 6-161.

not, check the rack-piston nut and

(3) Remove sector gearshaft assembly as

outlined in paragraph 6-154.

6-40