SECTOR GEARSHAFT AND SIDE COVER INSTALLATION

TM 10-3930-623-34

2. Remove rack-piston end plug (46, figure 4-32)

6-81.

SECTOR GEARSHAFT AND SIDE COVER

by inserting a 1/2 inch drive socket extension into the

INSTALLATION.

square hole in the plug and turning counterclockwise.

1. Lubricate new side cover packing (31), figure

4-32) and install in groove in face of side cover (30).

6-85. RACK-PISTON END PLUG INSTALLATION.

2. Turn stub shaft (76) as necessary until the

1. Turn plug into rack-piston and tighten to 50 to

middle rack groove is aligned with center of gearshaft

100 foot-pounds.

needle bearing (82).

2. Install housing end plug as outlined in paragraph

3. Install gearshaft (37) so that center tooth in the

6-83.

sector meshes with the center groove of rack on ball nut

(65). Make sure that side cover packing is in place

6-86. RACK-PISTON, WORM ASSEMBLY AND GEAR

before pushing side cover down on gear housing.

HOUSING ASSEMBLY REMOVAL.

4. Install side cover screws (28) and tighten to 30

1. Remove rack-piston end plug (46, figure 4-32)

to 35 foot-pounds.

as outlined in paragraph 6-84.

5. Install lash adjuster nut (34) on lash adjuster

2. Remove sector gearshaft assembly as outlined

without tightening. Adjust gearshaft (refer to paragraph

in paragraph 6-77.

6Hold lash adjuster from rotating with a hex key wrench

and tighten lash adjuster nut to 20 to 30 foot-pounds.

3. Insert rack-piston arbor (see figure 6-12 for tool

details) through ball nut (65, figure 4-32.) in end of worm

(59). Rotate stub shaft (76) to left tern, which will force

6-82. HOUSING END PLUG REMOVAL.

rack-piston ball nut onto arbor, and remove rack-piston

1. Rotate end plug retainer ring (44, figure 4-32) so

ball nut from gear housing (87). Take care to keep arbor

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

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

Spring one end of ring with punch to allow screwdriver to

nut is being removed to replace the piston ring (60) and

be inserted to lift ring out.

back-up packing (61), reassemble without further

disassembly.

2. Rotate stub shaft (76) with 3/4 inch box end or

4. Remove valve assembly as outlined in

socket wrench to left turn comer position and force end

paragraph 6-72.

plug (43) out of housing.

5. Remove worm (59), lower thrust bearing (68)

and races (67).

CAUTION

Do not rotate further than necessary,

or balls from rack and worm

6-87. RACK-PISTON, WORM ASSEMBLY AND GEAR

assembly will fall off the end of the

HOUSING DISASSEMBLY.

worm.

1. Cut piston ring (60, figure 4-32) and back-up

3. Remove and discard housing end plug packing

packing (61), remove from rack-piston ball nut (65) and

(45).

discard.

2. Remove screws and lock washers (63) from

6-83. HOUSING END PLUG INSTALLATION.

1. Lubricate new housing end plug packing (45)

rack-piston ball nut with screwdriver.

with OE-10 engine oil, and install in gear housing (87).

3. Remove ball return guide clamp (62).

2. Insert housing end plug (43) into gear housing

and at against packing.

4. Place the assembly on a clean cloth and remove

ball return guides (64) and arbor. Make sure all of the

3. Install end plug retainer ring (44) with fingers.

balls (66) are caught on the cloth.

Install one end of ring and work ring into groove until

seated. Slight tapping may be required to securely

6-88. RACK-PISTON, WORM ASSEMBLY AND GEAR

bottom retainer ring in gear housing (87).

HOUSING INSPECTION.

1. Inspect housing assembly (87, figure 4-32). If

6-84. RACK PISTON END PLUG REMOVAL.

bore is badly scored or worn, replace housing. If flare

1. Remove housing end plug as outlined in

fitting connectors (85 and 86) are badly brinelled or

paragraph 6-82.

scored, replace them.

To remove connectors, tap

threads in connectors with a 5/16-18 tap. Thread a bolt

with nut and flat washer attached (washer between nut

and gear housing) into tapped hole. Hold bolt while

turning nut off bolt. This will pull connector from gear

housing. Discard connectors.

6-21