Disassembly

If broken components or foreign materials are found during disassembly of the gear, the hydraulic system should be inspected, cleaned and flushed before service is complete.
The ball nut and control rings are not generally replaced unless cut or damaged. If replacing, inspect all mating parts for burrs, cracks, scratches or damage. Replace or repair as needed.

Fig. 1 Exploded view of power steering gear:

Fig. 2 Rack piston plug removal:

Fig. 3 Bearing removal:

Refer to Fig. 1, when performing the following procedures.
1. Pry retaining ring out of housing groove with a screwdriver.
2. Turn stub shaft to the left until plug on opposite end is forced out of cylinder, then remove seal.
3. Remove plug from rack piston, Fig. 2.
4. Remove nut, bolt, side cover and gasket, then turn adjuster screw right until side cover separates from pitman shaft.
5. Remove piston shaft, then turn stub shaft left until pitman shaft teeth and rack piston disengage.
6. Remove retaining ring, washers and seals, then remove bearing with bearing removal tool No. J-6278 or equivalent if necessary. Fig. 3.
7. Remove rack piston and balls as follows:
a. Insert ball retainer tool J-21552 or equivalent into rack piston bore with pilot seated into end of worm, refer to Fig. 2.
b. Hold tool against worm and turn stub shaft to left. Rack piston will be forced onto the tool.
c. Hold tool and pull rack piston toward handle until it is against flange. This will prevent end circuit balls from falling out.

Fig. 4 Adjuster plug removal:

Fig. 5 Needle bearing removal:

Fig. 6 Worm shaft & valve body removal:

Fig. 7 Stub shaft pin disengage:

8. Remove adjuster nut, then remove adjuster plug using spanner wrench tool J-7624 or equivalent, Fig. 4.
9. Disassemble adjuster plug as follows:
a. Remove retaining ring, washer, seal and bearing.
b. Remove bearing retainer by prying at raised area, then remove seal and needle bearing with adjuster plug bearing installer tool J-8524-2 and driver tool J-7079-2 or equivalents, Fig. 5.
10. Remove valve and worm shaft as an assembly with both races and bearing. Separate as follows:
a. Remove worm shaft from valve body, Fig. 6.
b. Remove races and bearing from worm shaft, them remove seal.
11. Remove stub shaft from valve body as follows:
a. Hold assembly and lightly tap stub shaft against a bench until shaft cap is free from valve body, Fig. 7.
b. Pull shaft assembly until shaft cap clears valve body by approximately 1/4 inch.
c. Remove valve spool and seals.
12. Remove screws, clamp and ball guide from rack piston, then remove balls.
13. Remove connectors from housing.