For 1990-2009 cars

## Integral Steering Gear Disassemble Saginaw

### Disassembly Procedure

#### Tools Required

• | J 21552 Rack Piston Arbor

• | J 7624 Spanner Wrench

• | J 6222-A Seal Shaft Protector

1. Remove the housing end plug. Refer to Steering Gear Housing Plug Replacement - Off Vehicle .
2. Remove the side cover. Refer to Steering Gear Pitman Shaft and Housing Cover Replacement - Off Vehicle .
3. Turn the stub shaft (4) clockwise until the pitman shaft teeth (1) and the primary rack piston (3) and the secondary rack piston (2) are disengaged.
4. Turn the stub shaft (4) clockwise until the primary rack piston (3) bottoms in the steering gear housing.
5. Align the end tooth of the pitman shaft with the center groove of the primary rack piston (1) and the secondary rack piston (1).
6. Turn the stub shaft counterclockwise until the housing end plug separates from the steering gear housing.

Important: Do not remove the housing end plug from the secondary rack piston (1) unless replacement of the housing end plug is needed.

7. Remove the secondary rack piston (1).
8. Rotate the stub shaft clockwise until the pitman shaft teeth (2) are free of the rack.
9. Turn the pitman shaft teeth (2) until the teeth (2) are horizontal.
10. Insert J 21552 into the primary rack piston (1) bore with the pilot of J 21552 seated into the end of the pin and worm assembly.
11. Hold J 21552 against the pin and worm assembly while turning the stub shaft counterclockwise. The primary rack piston (1) will be forced onto J 21552 .
12. Hold J 21552 while pulling the primary rack piston (1) toward the handle until the primary piston rack touches the tool flange. This prevents the circuit balls from falling out of the primary rack piston (1).
13. Remove the primary rack piston (1) from J 21552 .
14. Remove the primary rack piston balls.
15. Remove pitman shaft from the steering gear housing (2) by tapping the end of the pitman shaft.
16. Remove the coupling shield retainer and lock nut (3) using a hammer (1) and a drift (2).
17. Slide J 6222-A over the end of the stub shaft.
18. Remove the adjuster nut assembly (2) using J 7624 .
19. Remove the thrust support assembly.

Important: Do not reuse damaged or worn parts by welding or straightening. Replace all bent, broken or worn parts.

20. Remove the following items as an assembly from the steering gear housing:

• | The valve body (6)

• | The worm shaft (5)

• | The thrust bearing race (4)

• | The roller thrust bearing (3)

• | The thrust bearing race (1)

21. Remove the worm shaft (5) from the valve body assembly (6).
22. Remove the thrust bearing races (2) (4) and the roller thrust bearing (3) from the worm shaft (1).
23. Clean all of the parts in cleaning solvent.
24. Blow dry all of the parts.

## Integral Steering Gear Disassemble TRW Ross

#### Tools Required

• | J 37612-A TAS65 Complete Tool Kit

• | J 36452-A Poppet Disassembly Tool

• | J 37071 Seal Installer

### Removal Procedure

Caution: Replace the steering gear mounting bolts, the washers and the nuts every time you remove the steering gear from the vehicle. Failure to replace the bolts, the washers and the nuts may cause the steering gear to separate from the vehicle. This could cause a loss of steering control and personal injury.

1. Use a small screwdriver in order to remove the dust seal (1).
2. Remove the snap ring (2).
3. Rotate the input shaft and valve worm assembly. Rotate the assembly until the timing mark on the end of the sector shaft (12) is aligned with the timing mark on the end of the housing trunnion.
4. Use a fine grade emery cloth in order to remove any paint or corrosion from the exposed area of the sector shaft (12).
5. Remove the sector shaft adjusting screw jam nut.
6. Use one layer of masking tape in order to tape the serrations and the bolt groove on the sector shaft (12). Ensure that the tape does not extend onto the sector shaft bearing diameter.
7. Remove 6 bolts (19) from the side cover (17). The bolts are equipped with a ring on the underside of the head. Replace the bolts with the same type and length as necessary.
8. Remove the side cover (17) and the sector shaft (12) from the gear assembly (9) as a unit.
9. Tap the end of the shaft lightly with a soft mallet. More fluid will drain from the gear.
10. Remove the gasket (16).
11. Turn the sector shaft adjusting screw (13) clockwise.
12. Remove the sector shaft (12) out of the side cover (17).
13. Clamp the side cover in a vise.
14. Screw a ½-20 UNF 2Ax3 in bolt (1) into the side cover adjusting screw hole. Ensure that the bolt end is positioned in order to support a rolling head type pry bar.
15. Support a pry bar in the bolt end of the seal.

Use the pry bar in order to pry out the seal from the side cover.

Do not damage the seal bore or the bearing surface.

16. Remove the bolt (1).
17. Remove the vent plug (2).
18. Inspect the adjusting screw (7) for damaged threads. The screw must rotate by hand without perceptible end play.
19. Inspect the retainer (6) . The retainer must be locked in place without cracks.
20. Place the sector shaft (8) firmly into a soft jawed vice. Use a suitable chisel in order to unstake the retainer (6).
21. Turn the retainer (6) out of the sector shaft pocket.
22. Remove the adjusting screw (7).
23. Remove the relief valve cap (4), if equipped.
24. Remove the O-ring (3), if equipped.
25. Remove the two piece relief valve (2), if equipped.
26. Remove the seal (8).
27. Use a fine grade emery cloth in order to clean any paint or corrosion from the exposed area of the input shaft (7).
28. Remove the bolts (5).
29. Remove the following components as a unit from the housing:

• | The valve housing

• | The input shaft

• | The rack piston

30. Place the assembly on a clean cloth in order to catch the balls during the rack piston (3) disassembly.

Do not remove the poppet adjuster seat and the sleeve assemblies (2) unless the components will be replaced.

Do not disturb the position of the poppet adjuster seat unless the poppet adjuster seat will be replaced.

31. Remove the seal rings.
32. Remove the screws (6).
33. Remove the cap (7).
34. Remove the seal (8).

Important: Do not remove the input shaft, valve, worm assembly, or balls from the rack piston until the ball return guides are removed or damage to the ball guides will occur.

35. Remove the ball return guide halves (5). Insert a small screwdriver between the rack piston (3) and guides (5).
36. Remove the 32 steel balls (4):

36.1. | Rotate the input shaft until all of the balls fall out.

36.2. | The steel balls are a matched set. The set must be replaced if any of the balls are lost.

37. Remove the rack piston (1) from the input shaft.
38. Remove the Teflon® seal ring and the O-ring.
39. Remove the poppet assemblies, if necessary.
40. Place the rack piston (1) in a soft-jawed vice.
41. Use the J 36452-A in order to remove the larger diameter threaded adjuster sleeve (3).
42. Slide the J 36452-A over the seat of the poppet adjuster seat and sleeve assemblies in the rack piston (1).
43. Engage the tool in the slots in the threaded sleeve.
44. Hit the end of the tool firmly 3-4 times with a 0.45 kg (16 oz) hammer (2) in order to loosen the Loctite that was applied during assembly.
45. Apply the breaker bar to the tool.

Use the tool in order to turn the adjuster seat and the assemblies out of the rack piston (1).

Notice: The sleeve is retained with thread locking compound. A new rack piston and poppet assembly will be required if they are damaged while removing the sleeve.

46. Remove the poppet fixed stop screw (1) and the washer (2), if necessary.
47. Remove the grease fitting (4), if necessary.
48. Remove the seal (7).

Use a small screwdriver in order to remove the seal. Do not damage the sealing area of the bore.

49. Remove the bearing (6), if necessary.
50. Place the J 37071 against the side cover end of the bearing.

Press the bearing out of the trunnion end of the bearing bore.

51. Ensure that the J 37071 clears the retaining ring.
52. Remove the retaining ring, if necessary. Remove the retaining ring through the trunnion end of the bearing bore in order to protect the pressure seal bore area.