FORD MUSTANG 1969 Volume One Chassis

03-08-07
Ford Design Integral Power Steering Gear

03-08-07

Press Ram
Tool-

T65P.3524-A1

G1362-A

FIG.
17—Installing
Oil Seal in

Valve Housing

11.
Place the dust seal in the hous-

ing with the dished side (rubber side)

facing out. Drive the dust seal into

place with the tool shown in Fig. 11.

the seal must be located behind the

undercut in the input shaft when it is

installed.

Worm and Valve

1.
Remove the snap ring from the

end of the actuator.

2.
Slide the control valve spool

(Fig. 6) off the actuator.

3.
Install the valve spool evenly and

slowly with a slight oscillating motion

into the flanged end of valve housing

with the Valve identification groove

between the valve spool lands out-

ward, checking for freedom of valve

movement within the housing working

area. The valve spool should enter the

housing bore freely and fall by its own

weight.

4.
If the valve spool is not free,

check for burrs at the outward edges

of the working lands in the housing

and remove with a hard stone.

5.
Check the valve for burrs and if

burrs are found, stone the valve in a

radial direction only. Check for free-

dom of the valve again.

6. Remove the valve spool from the

housing.

7.
Slide the spool onto the actuator

making, sure that the groove in the

spool annulus is toward the worm.

8. Install the snap ring to retain the

spool.

9. Check the clearance between the

spool and the snap ring. The clearance

should be between 0.002-0.005 inch. If

the clearance is not within these lim-

its,
select a snap ring that will allow a

clearance of 0.003 inch.
STEERING GEAR HOUSING

J

UPPER SEAL

I LOWER SEAL

SNAP RING

SPACER WASHER

FIG. 12—Steering Gear Housing Disassembled

Tool - T59L - 100-B

Tool T57L-500 - A

G1551-A

FIG. 13—Removing Lower Seal

Piston and Ball Nut

1.
Remove the teflon ring and the

O-ring (Fig. 7) from the piston and

ball nut.

2.
Dip a new O-ring in gear lubri-

cant and install it on the piston and

ball nut.

3.
Install a new teflon ring on the

piston and ball nut being careful not

to stretch it any more than necessary.

Steering Gear Housing

1.
Remove the snap ring and the

spacer washer (Fig. 12) from the

lower end of the steering gear housing.

2.
Remove the lower seal from the

housing as shown in Fig. 13. Lift the

spacer washer from the housing.

3.
Remove the upper seal in the

same manner as the lower seal.

4.
Dip both sector shaft seals in

gear lubricant.
SHORT END

AWAY

FROM SEAL
G1550-A

Press Rom

G1374-A

FIG. 14—Installing Sector Shaft

Inner Seal

5. Apply Lubricant to the sector

shaft seal bore of the housing and

position the sector shaft inner seal

into the housing with the lip facing in-

ward. Press the seal into place with

the tool shown in Fig. 14. Place a spa-

cer washer (0.090 inch) on top of the

seal and apply more Lubricant to the

housing bore.

6. Place the outer seal in the hous-

ing with the lip facing inward and

press it into place as shown in Fig. 15.

Then, place a 0.090 inch spacer wash-

er on top of the seal.

7.
Position the snap ring in the

housing. Press the snap ring into the

housing with the tool shown in Fig. 15

to properly locate the seals and en-

gage the snap ring in the groove.

STEERING GEAR

ASSEMBLY

Do not clean, wash, or soak seals in

cleaning solvent.procarmanuals.com

03-08-08
Ford Design Integral Power Steering Gear

03-08-08

LONG END

AWAY FROM

SEAL
Press Ram

G1375-A

FIG. 15— Installing Sector Shaft

Outer Seal

1.
Mount the valve housing in the

holding fixture with the flanged end

up.

2.
Place the required thickness

valve spool centering shim (Fig. 6) in

the housing. Use one shim only.

3.
Carefully install the worm and

valve in the housing.

4.
Install the attaching nut in the

housing and torque it to specification

(Part 3-13).

5.
Install the lock nut (Fig. 7) and

torque it to specification (Part 3-13).

6. Place the piston on the bench

with the ball guide holes facing up.

Insert 44ie worm shaft into the piston

so that the first groove is in alignment

with the hole nearest to the center of

the piston (Fig. 16).

7.
Place the ball guide in the pis-

ton. Place the 27 balls in the ball

guide (Fig. 16) turning the worm in a

clockwise direction as viewed from the

input end of the shaft. If all of the

balls have not been fed into the guide

upon reaching the right stop, rotate

the input shaft in one direction and

then in the other while installing the

balls.
After the balls have been in-

stalled, do not rotate the input shaft
FIRST GROOVE OF WORM SHOULD BE IN

ALIGNMENT WITH THIS HOLE

G1554-A

FIG. 16—Assembling Piston on Worm Shaft

INPUT SHAFT

SECTOR
SHAFT

ADJUSTMENT
SCREW

G1547-A

FIG. 77—Adjusting Mesh

or the piston more than 3 1/2 turns

off the right stop to prevent the balls

from falling out of the circuit.

8. Secure the guides in the ball nut

with the clamp (Fig. 6).

9. Position a new lube passage O-

ring in the counterbore of the gear

housing.
10.
Apply vaseline to the teflon seal

on the piston.

11.
Place a new O-ring on the valve

housing.

12.
Slide the piston and valve into

the gear housing being careful not to

damage the teflon seal.

13.
Align the lube passage in the

valve housing with the one in the gear

housing, and install but do not tighten

the attaching bolts.

14.
Rotate the ball nut so that the

teeth are in the same plane as the sec-

tor teeth. Tighten the four valve hous-

ing attaching bolts to specifications.

15.
Position the sector shaft cover

O-ring in the steering gear housing.

Turn the input shaft as required to

center the piston.

16.
Apply vaseline to me sector

shaft journal then position the sector

shaft and cover assembly in the gear

housing. Install the steering identifica-

tion tag and two sector shaft cover at-

taching bolts. Torque the bolts to spe-

cifications.

17.
Attach an in-lb torque wrench

to the input shaft. Adjust the mesh

load to specifications as shown in Fig.

17.procarmanuals.com

03-09-01
Saginaw Design Integral Power Steering Gear

03-09-01

PART 3-9 Saginaw Design

Integral Power Steering Gear

COMPONENT INDEX

STEERING GEAR

Cleaning and Inspection (See Page 03-01)

Description

Disassembly and Assembly

Mesh Load Adjustment

Removal and Installation

Overhaul
MODEL APPLICATION
All
Models
Ford

09-01

09-03

09-01

09-02

09-04
Mercury
N/A

N/A

N/A

N/A

N/A

N/A
Meteor
N/A

N/A

N/A

N/A

N/A

N/A
Cougar
N/A

N/A

N/A

N/A

N/A

N/A
Fairlane
N/A

N/A

N/A

N/A

N/A

N/A
Falcon
N/A

N/A

N/A

N/A

N/A

N/A
Montego
N/A

N/A

N/A

N/A

N/A

N/A
Mustang
N/A

N/A

N/A

N/A

N/A

N/A
Lincoln-
Continental
N/A

N/A

N/A

N/A

N/A

N/A
Thunderbird
N/A

N/A

N/A

N/A

N/\

N/A
Continental-
Mark III
N/A

N/A

N/A

N/A

N/A

N/A

A page number indicates that the item is for the vehicle listed at the head of the column.

N/A indicates that the item is not applicable to the vehicle listed.

DESCRIPTION

The Rotary Valve Safety power

steering gear operates entirely on dis-

placing fluid to provide hydraulic fluid

pressure assists only when turning. As

the entire gear assembly is always full

of fluid, all internal components of the

gear are immersed in fluid making

periodic lubrication unnecessary. In

addition, this fluid acts as a cushion
to absorb road shocks that may be

transmitted to the driver. All fluid

passages are internal except the pres-

sure and return hoses between the

gear and pump.

The rotary valve provides a smooth

transmission through the driving range

of steering wheel effort. A torsion bar

transmits the road feel to the driver.
Response of the steering gear to effort

applied to the steering wheel has been

greatly increased.

The rack-piston nut is one piece and

is geared to the sector shaft. Lash be-

tween the sector shaft and rack-piston

nut is maintained by an adjusting

screw which is retained in the end o\'

the shaft uear (Eiiz.l).

IN-VEHICLE ADJUSTMENTS AND REPAIRS

During the breaking in period of

the vehicle, it is probable that some

of the factory adjustments will change.

These changes in adjustment do not

necessarily affect the satisfactory op-

eration of the steering gear assembly

and ordinarily do not require re-ad-

justment unless there is excessive lash

or other malfunctioning. The only ad-

justment that should be performed in

the vehicle is the total over center

position load (mesh load) to eliminate

excessive lash between the sector shaft

and rack teeth.

MESH LOAD ADJUSTMENT

1.
Disconnect the Pitman arm from
the sector shaft and remove the steer-

ing wheel hub.

2.
Disconnect the fluid return line

at the reservoir; at the same time cap

the reservoir return line pipe.

3.
Place the end of the return line

in a clean container and cycle the

steering wheel in both directions as

required, to discharge the fluid from

the gear.

4.
Turn the gear 1/2 turn off cen-

ter (either direction). Using a 24 in-

lb torque wrench on the steering wheel

nut, determine the torque required to

rotate the shaft slowly through a 20

degree arc.

5.
Turn the sear back to center and
repeating the method of reading tor-

que as in Step 4, above, loosen the

adjuster lock nut, turn the screw in-

ward with a 7/32-inch Allen wrench

until the reading is equal to 6 in-lbs

in excess of Step 4 above, and retigh-

ten the lock nut while holding the

screw in place.

6. Recheck the readings and re-

place the Pitman arm and the steering

wheel hub.

7.
Connect the fluid return line to

the reservoir and fill the reservoir

with C1AZ-I9582-A Fluid to the

proper level.
procarmanuals.com

03-09-02

Saginaw Design Integral Power Steering Gear

03-09-02

WORM

ADJUSTER PLUG

TORSION BAR

STUB SHAFT

SEAL

NEEDLE BEARINGS

TEFLON RING

TEFLON SEALS

SECTOR SHAFT

FIG.l —
Power
Steering Gear—Sectional View
G 1650-A

REMOVAL
AND
INSTALLATION

REMOVAL

1.
Disconnect
the
pressure
and the

return line from
the
steering gear.

Plug
the
lines
and the
ports
in the

gear to prevent entry of dirt.

2.
Remove the two bolts that secure

the flex coupling
to the
steering gear

and
to
the column.

3.
Raise
the
vehicle
and
remove
the

Pitman arm attaching nut.

4.
Remove
the
Pitman arni from

the sector shaft with Tool T64P-3590-

F.
Remove
the
tool from
the
Pitman

arm.

5.
If
working
on a
vehicle equipped

with
a
standard transmission, remove
the clutch release lever retracting spring

to provide clearance
for
removing
the

steering gear.

6. Support
the
steering gear then

remove
the
three steering gear attach-

ing bolts.

7.
Work
the
steering gear free
of

the flex coupling
and
remove
it
from

the vehicle.

8.
If
the flex coupling stayed
on the

input shaft, lift
it off the
shaft
at

this time.

INSTALLATION

1.
Slide
the
flex coupling into place

on
the
steering shaft. Turn
the
steer-
ing wheel
so
that
the
spokes
are in

the horizontal position.

2.
Center
the
steering gear input

shaft.

3.
Slide the steering gear input shaft

into
the
flex coupling
and
into place

on
the
frame side rail. Install the three

attaching bolts
and
torque them
to

specification.

4.
Make sure that
ihe
wheels
are

in
the
straight-ahead position, then

install
the
Pitman
arm on the
sector

shaft. Install
and
tighten
the
sector

shaft attaching nut to specification.

5.
Move the flex coupling into place

on
the
input shaft
and
steering columnprocarmanuals.com

03-09-03
Saginaw Design Integral Power Steering Gear

03-09-03

shaft and install and tighten the attach-

ing bolts to specification.

6. Connect and tighten the fluid
pressure and the return line to the

steering gear.

7. Fill the power steering pump and
cycle the steering gear. Check for

leaks.
Check the reservoir fluid level

again and add as required.

MAJOR REPAIR OPERATIONS

Disassembly and reassembly of the

unit and the subassemblies must be

made on a clean workbench. As in re-

pairing any hyldraulically operated

unit, cleanliness is of tftfiiost impor-

tance. Therefore, the bench, tools, and

parts must be kept clean at all times.

Thoroughly clean the exterior of the

gear with a suitable solvent and, when

necessary, drain as much of the hy-

draulic fluid from the gear as possible.

DISASSEMBLY INTO

SUB-ASSEMBLIES

1,
Mount the steering gear in a

vise.
(Fig..
2\

2.
Rotate the end plug retaining

ring to place one end of the ring

opposite the hole in the housing.
3.
Working through the hole in the

housing (Fig. 3), unseat the retaining

ring then work it out of the groove

with a screwdriver.

4.
Rotate the input shaft in a coun-

terclockwise direction using a 3/4

inch, 12-point socket wrench to force

the end plug out of the housing. Do

not rotate the shaft any more than

necessary to remove the plug. Further

rotation will allow the balls to fall

from their circuit and allow the rack-

piston to become disengaged from the

sector shaft. Remove the O-ring from

the housing and discard it.

5.
Rotate the input shaft 1/2 turn

in a clockwise direction to draw the

piston inward.

6. Turn the end plug (Fig. 4) count-

erclockwise out of the piston with a

1/2 inch drive extension.
7.
Remove the lock nut from the

sector shaft adjustment screw. Discard

the nut.

8. Remove the four cover attaching

screws. Rotate the sector shaft adjust-

ment screw with an Allen wrench until

the cover is free of the housing. Re-

move the cover and the O-ring. Dis-

card the O-ring.

9. Turn the input shaft as required

to center the sector shaft teeth in the

housing.

10.
Tap the end of the sector shaft

with a soft-faced hammer to free it

from the housing.

11.
Remove the adjuster plug lock

nut.

12.
Remove the adjuster p>ug with

spanner wrench T65P-3A537-A (Fig.

15).

13.
Insert the tool shown ir Fig. 6

LOCK NUT RETUF™ P0RT

INLET PORT

TORSION BAR

STUB SHAFT
SECTOR SHAFT

ADJUSTMENT SCREW

ADJUSTER PLUG

HOUSING

SECTOR SHAFT

G
1649-
A

FIG. 2—Steering Gear
END PLUG

G1648-A

FIG. 3—Removing End Plug

Retaining Rinaprocarmanuals.com

03-09-04
Saginaw Design Integral Power Steering Gear

03-09-04

CLAMP

BALL
RETURN GUIDE
TEFLON
RINGS (3)

VALVE
SPOOL

0-RING SPOOL

SEAL

INLET
PORT SEAT

CHECK
VALVE

RETURN
PORT

SEAT

SPRING
STUB
SHAFT

ASSEMBLY

TEFLON
RING

RACK-PISTON
END PLUG

O-RING

HOUSING
END PLUG

RETAINING
RING
FLEXIBLE

COUPLING

'BEARING
LOCK

NUT

GROUND
STRAP

RETAINING
RING

DUST
SEAL

OIL
SEAL

ADJUSTER
PLUG

O-RING SEAL

THRUST
BEARING

SPACER

BEARING
RETAINER

SPOOL
SPRING

RETAINING
RING

FIG. 4—Steering Gear Disassembled

SPANNER
WRENCH

Tool - T65P-

lG
1646-A

FIG. 5—Removing Adjuster Plug
14.
Pull the stub shaft and valve as-

sembly from the housing.

15.
Lift the worm, lower thrust

bearing and the races from the hous-

ing.

REPAIR
OF SUB-

ASSEMBLIES

Do not clean, wash, or soak seals in

cleaning solvent.

STEERING GEAR HOUSING

1.
Remove the snap ring (Fig. 7)
G
1647-A

that secures the sector shaft seals in

the lower end of the housing. Remove

the lower spacer washer.

2.
Remove the lower seal (double

lip),
spacer washer, upper seal (single

lip) with Tools T85L-1O1-A and

T59L-100-B (Fig. 8).

3.
Check the housing bearing for

wear and remove the bearing only if

worn or damaged. Working from the

lower end of the housing (Fig. 9) press

the bearing out of the housing. Dis-

card the bearing.

.HOUSING
LOWER
SEAL (DOUBLE LIP)

Tool
- T 65P-3D517-A

G
1645-A

FIG. 6—Removing Rack Piston

into the end of the rack-piston until it

contacts the worm shaft. Rotate the

stub shaft in a counterclockwise direc-

tion until the worm is free of the

rack-piston. Withdraw the rack-piston

from the housing making sure that the

tool is held all the way in the piston

to prevent dropping the balls. Do not

disassemble the rack-piston at this

time.
SNAP

RING

INLET
PORT

SEAT

RETUkN
PORT

SEAT

G
1643-A

FIG. 7—Steering Gear Housing Disassembledprocarmanuals.com

03-09-05
Saginaw Design Integral Power Steering Gear

03-09-05

Tool . T59L -100S

FIG. 8—Removing Sector

Shaft Seals

Too/
-
T65P -3576-C

G 1641-A

FIG. 9—Removing Sector

Shaft Bearings

4.
Working from
the
upper
end of

the housing, press
in a new
bearing

until
the
upper
end
is
0.030 inch below

the housing bore. When installing
the

bearing, make sure
it is
pressed
in

from
the
identification
end
(stamped

end).

5.
Lubricate
new
sector shaft seals

(Fig.
7) in
C1AZ-19582-A hydraulic

fluid. Install
the
single
lip
seal first,

then
a
back-up washer. Using special

tool
(Fig. 10),
drive
the
seal
and
wash-

er
in far
enough
to
provide clearance

for
the
other seal
and
back-up washer

and
the
retaining ring.
The
seal must

not bottom
on the end of
the
counter-

bore.
Install
the
double
lip
seal
and

the second back-up washer. Again using
the special tool, drive
the
seal
and

back-up washer
in
only
far
enough
to

provide clearance
for the
retaining

ring. Install
the
sector shaft seal
re-

taining ring with snap ring pliers,

making certian that
the
ring
is
seated

properly.

6.
To
remove
a
damaged port seat,

use
a
5/16-18 inch
U.S.
thread

(coarse)
tap and
turn
it
two
turns into

the seat.

7.
Thread
a
bolt
and nut
with
a
flat

washer into
the
tapped hole
(Fig.
11).

8. Hold
the
bolt from turning
and

tighten
the nut to
extract
the
seat.

Discard
the
seat.

9. Remove
the
check valve
and

spring from
the
inlet port.

10.
Blow
all
chips from
the
hous-

ing.

11.
Position
the
spring, check valve

and
new
seat
in the
inlet port.

12.
Use the
tool shown
in Fig. 12

and drive
the
seat into place.

.
T65P-3D642-A

G1287-
A

FIG.
10
— Installing Sector

Shaft Seal

5/16
•
16x2"

BOLT
13.
Install
the
outlet port seat
in

the same manner.

ADJUSTER PLUG

1.
Lift
the
adjuster plug
off
the
stub

shaft
(Fig.
4).

2.
Pry the
thrust bearing retainer

off
the
adjuster plug
as
shown
in Fig.

13.
Be
careful
not to
score
the
needle

bearing bore. Discard
the
retainer.

3.
Lift
the
spacer, thrust bearing,

races
and the
O-ring, from
the
plug

(Fig.
14).
Discard
the
O-ring.

4.
If
necessary
to
replace
the
roller

bearing, remove
the
dust seal retaining

ring. Working from
the
spacer
end of

the adjuster plug, remove
the
roller

bearing,
oil
seal
and the
dust seal
as

shown
in Fig. 15.

G1639-A

FIG.
12
-Installing Inlet Port

BEARING RETAINER

G1640-A

FIG. 11 —Removing Port Seat
C1638-A

FIG. 73—Removing Thrust

Bearing Retainer

If
the
roller bearing does
not
need

replacing
do not
remove
it. Pry the

dust seal
and the oil
seal from
the ad-

juster plug with
a
screwdriver.

5.
Place
a new
roller bearing
on the

tool shown
in Fig.
15
with
the
bearing

manufacturer's identification facing

toward
the
tool.

6. Position
the
bearing
and
tool
in

the bore. Drive
the
bearing into
the

plug until
it is
flush with
the
bottom

surface
of the
stub shaft seal bore.

7.
Lubricate
a new oil
seal with

C1AZ-19582-A. Install
the
seal with

Tool T65P-3D536-A pressing
it
intoprocarmanuals.com

03-09-06
Saginaw Design Integral Power Steering Gear

03-09-06

ADJUSTER
PLUG

DUST
SEAL

FIG. 14 —Adjuster Plug Disassembled

the plug far enough to provide clear-

ance for the dust seal and the snap

ring.

8. Lubricate a new dust seal

C1AZ-19582-A and install it with

smooth rubber surface facing outward.

9. Secure the dust seal with the

ring, making sure that the ring is

properly seated.

10.
Lubricate a new O-ring seal

with vaseline and install it on the ad-

juster plug.

11.
Assemble the thrust bearing

outer race, thrust bearing, inner race,

and the thrust bearing spacer on the

adjuster plug (Fig. 16).
OIL
RETAINING

SEAL
RING

G
1637-A

12.
Press a new bearing retainer

into the bearing bore. The radial loca-

tion of the dimples is not important.

STUB SHAFT AND

VALVE ASSEMBLY

The control valve and spool is a se-

lect fit and cannot be serviced other

BEARING
AND

RACES

1636-A

FIG. 15 —Removing or Installing

Roller Rearing from Adjuster Plug
G
1635-A

FIG.
76
—Installing Thrust

Bearing Retainer

SPOOL
SPRING

DOWEL
BEARING

RACE

G1634-A

FIG. 77—Control Valve Disassembled
than removing the spool to replace the

dampener O-ring or replace the three

teflon seals or O-rings under the teflon

seals.

1.
Remove the cap to worm O-ring

and discard it (Fig. 17).

2.
Work the rear coil of spool

spring onto the stub shaft bearing sur-

face.
Do not pry on the valve body.

Slide the spring off the shaft.

3.
Extreme care must be used when

removing the valve spool. The diame-

tral clearance between the valve body

and the spool may be as low as 0.0004

inch. The slightest cocking of the

spool may jam it in the valve body.

a. To remove the valve spool, hold

the valve assembly in both hands with

the stub shaft pointing downward.

Push lightly on the valve spool with a

small rod by inserting the rod through

the openings in the end cap (Fig. 18)

until the spool is far enough out of the

valve so that it may be grasped by the

hand. Withdraw the spool with a

steady oscillating pull to prevent jam-

ming. If slight sticking occurs, make a

gentle attempt to reverse the with-

drawal procedure. If this does not free

the spool, it has become cocked in the

valve body bore. Do not attempt to

force the spool in or out if it becomes

cocked. In this case, continue to disas-

semble the valve assembly as follows

and return to the spool as described

later. Remove the stub shaft, torsion

bar, and end cap assembly by holding

the thumbs on the valve body as

shown in Fig. 18. Tap the torsion bar

lightly against the workbench. This

will dislodge the cap from the valve

body to cap pin. The stub shaft, tor-

sion bar and end cap assembly can

now be removed from the valve body.

b.
If the valve spool has become

cocked as described in step 3 above, it

can now be freed. By visual inspection

on a flat surface it can be determined

in which direction the spool is cocked.

A few very light taps with a light soft

plastic or raw-hide mallet should align

the spool in the bore and free it. Do

not tap with anything metallic. If

spool can be rotated, it can be re-

moved.

4.
Remove O-ring dampener seal

from the spool and discard it.

5.
Carefully cut the valve rings and

the ring back-up seals, remove and

discard them, providing the rings show

evidence of excessive wear. The valve

rings are made of filled teflon and it is

very unusual that replacement is re-

quired.

6. Remove the dampener O-ring

from the valve spool and discard it.procarmanuals.com

03-09-07

Saginaw Design Integral Power Steering Gear

03-09-07

VALVE SPOOL

DAMP EN
ERO-RING

TORSION BAR

G 1633-A

FIG. 18 —Removing Spool

from Valve Body

7.
Dip three new valve body O-

rings and teflon rings in C1AZ-

19582-A lubricant. Install the O-rings

on the valve body being careful not to

twist them. Slide the three teflon rings

into place over the O-rings being care-

ful not to stretch them any more than

necessary.

8. Lubricate a new dampener O-

ring and install it in the spool groove.

9. Assemble the stub shaft in the

valve body making sure that the

groove in the cap engages the pin in

the body. Tap the cap lightly with a

soft-faced hammer to seat it in the

valve body.

10.
Dip the valve spool in C1AZ-

19582-A. With the notch of the spool

toward the valve body, carefully slide

the spooi over the shaft and into the

body rotating it slightly to permit easy

entry. Make sure that the dampener

O-ring is distributed evenly to prevent

TEFLON RING
damage. Guide the spool to engage

the notch with the dowel in the body.

11.
Place the spool spring on the

stub shaft with the larger diameter

toward the spool. Work the small end

of the spring down over the shaft until

the small end is seated in the groove

of the stub shaft.

12.
If, during the assembly of the

valve, the stub shaft and end cap as-

sembly is allowed to slip out of en-

gagement with the valve body pin, the

spool will be permitted to enter the

valve body too far. The dampener O-

ring seal will expand into the valve

body fluid grooves preventing with-

drawal of the spool. Attempt to with-

draw the spool with a slight pull and

much rotary motion. If this does not

free the spool after several tries, make

sure that the spool is free to rotate;

place the valve body on a flat surface

with the notched end up, and tap the

spool with a wooden or plastic rod

until the O-ring seal is cut and the

spool can be removed. Replace the

dampener O-ring seal and proceed

with the assembly procedure as be-

fore.

RACK-PISTON

1.
Cut the teflon ring and the O-

ring from the piston.

2.
Place the assembly on a clean

lint-free cloth and remove the screws

that attach the ball return guide clamp

to the rack piston and remove the

clamp (Fig. 19).

3.
Lift the ball return guides from

the rack-piston.

4.
Remove Tool T65P-3D517-A

from the piston and remove the re-

maining balls.

5.
Thoroughly clean all parts.

END PLUG

RACK PI STON

DARK COLORED BALLS

(11 REQUIRED)

V

0-RING

POLISHED BALLS

(II REQUIRED)

BALL RETURN GUIDE

CLAMP

B

G1296. A
6. Lubricate a new O-ring and tef-

lon ring. Install the O-ring on the pis-

ton being qareful not to twist it. Slide

the teflon ring into place being careful

not to stretch it any more than neces-

sary.

7.
Slide worm (Fig. 20) fully into

the rack-piston. Load 16 balls into the

guide hole nearest the teflon ring

while slowly rotating the worm count-

erclockwise to feed the balls through

circuit. Alternate the dark colored

balls with the polished balls through

the circuit.

TEFLON RING

FIG. 19—Rack-Piston Disassembled
G 1632-A

FIG. 20—Assembling Rack Piston

Apply Lubriplate liberally to one of

the ball return guides and install the

six remaining balls in the guide. Place

the other half of the guide in position

and insert them into holes in the

rack-piston. Be sure that the dark ball

in the guide is installed next to the

polished ball in the rack-piston. Install

the ball return guide clamp with

screws and lock washers. Tighten the

screws to 8-12 ft-lbs.

8. The worm groove is ground with

a high point in the center. V/hen the

rack-piston passes over this high point

there should be a preload of 1-4 in-

lbs.
Clamp the rack-piston in a vise

with soft jaws with the worm shaft

pointing up. To avoid distortion, do

not tighten the vise too tight.

9. Place the valve assembly on the

worm, engaging the worm drive pins.

Rotate the worm until it extends 1

1/4 inch from the rack-piston to the

thrust bearing face. This is the center

position.

10.
Place an in-lb torque wrench

with a 3/4-inch-deep wall 12-point

socket on the stub shaft, and rotate

the wrench through an arc of approxi-

mately 60 degrees in both directions

several times, then take a torque read-

ing. The highest average reading ob-

tained with the worm rotating should

be between 1-4 in-lbs.

11.
If this reading is too high or

too low a new set of balls should beprocarmanuals.com

03-09-08
Saginaw Design Integral Power Steering Gear

03-09-08

Code

Size

6

7

8

9

10

11
Diameter

Mean

0.28117

0.28125

0.28133

0.28141

0.28149

0.28157
Size Range of Ball

(Inch)

0.28112-0.28122

0.28120-0.28130

0.28128-0.28138

0.28136-0.28146

0.28144-0.28154

0.28152-0.28162

FIG. 21 —Worm Ball Sizes

installed. Service replacement balls are

available in the sizes shown in (Fig.

21).

12.
Note the ball size stamped on

the rack-piston and install the next

size larger balls to increase the pre-

load. If no number is stamped on the

rack-piston, the original ball code size

was No. 7.

A change of one ball size larger will

increase the preload approximately

one in-lb. Final preload on replace-

ment balls should be 2-3 in-lbs.

Remove the valve assembly from

the worm and the rack-piston from

the vise.

13.
Insert Tool T65P-3D517-A into

the plug end of the rack and piston to

contact the worm shaft (Fig. 22).

Apply pressure on the tool while ro-

tating the worm shaft out of the pis-

ton and rack. Leave the tool in place

until the piston is installed in the

housing.

END OF TOOL MUST BE IN

CONTACT WITH WORM

SHAFT

Tool * T65P-3D517-A

FIG. 22—Installing Tool

in Raek-Piston
G 1631-A
ASSEMBLY OF

STEERING GEAR

1.
Secure the steering gear housing

in a vise.

2.
Lubricate the worm shaft, lower

thrust bearing, and races; then posi-

tion the thrust bearing and races on

the worm.

Align the valve body drive pin on

the worm, with the narrow pin slot in

the valve body. Be sure O-Ring seal

between the valve body and the worm

head is installed.

3.
Position the valve assembly and

the worm shaft in the housing as a

unit (Fig. 23). Do not push against the

stub shaft as this could cause the stub

shaft and cap to pull out of the valve

body, allowing the spool seal to slip

into valve body fluid grooves. Install

the valve assembly by pushing on the

outer diameter of the valve body hous-

ing with the finger tips. Be sure that

the teflon rings are not binding inside

the housing. The valve assembly is

correctly seated when the fluid return

hole in the gear housing is fully vis-

ible.

4.
Place the tool shown in Fig. 24

over the end of the stub shaft.

5.
Lubricate a new adjuster plug

O-ring and install it in the adjuster

plug groove.

6. Install the adjuster plug over the

end of the stub shaft and tighten it

DRIVE PIN
just enough to be sure all parts are

properly seated. Remove Tool T65P-

3A537-B.

7.
Install the adjuster plug locknut

loosely on the plug.

8. Tighten the adjuster plug with

wrench J7624 while rotating the input

shaft. As soon as additional drag is

noted, back the adjuster plug off 1/8

turn. Measure the input shaft drag

with an in-lb torque wrench.

9. Tighten the adjuster plug (Fig.

25) to obtain a 1-3 in-lb preload in ex-

cess of the drag that was measured

previously. Tighten the adjuster plug

lock nut and recheck the thrust bear-

ing preload. Total preload must not

exceed 8 in-lbs.

10.
Install Tool T65P-3805-A in

the steering gear housing. Position the

rack-piston as shown in Fig. 26. Be

sure that Tool T65P-3D517-A is con-

tacting the worm shaft. Push the

rack-piston inward until it contacts

the worm shaft while keeping pressure

applied to Tool T65P-3D517-A. Turn

the stub shaft clockwise until the

middle rack groove in the rack-piston

is aligned with the center of sector

shaft roller bearing. Remove the tool

from the housing.

11.
Lubricate a new O-ring with

C1AZ-19582-A and position it in the

sector shaft cover.

12.
Thread the sector shaft cover

on the adjusting screw until it bottoms

then back it off 1 1/2 turns.

13.
Install the sector shaft so that

the center gear tooth meshes with the

center groove in the rack-piston. Be

sure that the cover O-ring is in place

before pushing the cover down on the

housing.

14.
Install the cover screws and

lock washers. Tighten to 30-35 ft-lbs.

15.
Install a new adjuster lock nut

halfway on the adjuster screw.

16.
Install the end plug in the

rack-piston. Tighten the plug to 50-

100 ft-lbs torque.

17.
Lubricate a new housing end

plug O-ring and install it in the hous-

ing.

18.
Place the end plug in the gear

housing and seat it against the O-ring

seal. It may be necessary to tap the

Tool
T65P-3A537-B

STUB SHAFT

ADJUSTER

PLUG

G 1630-A

FIG. 23—Installing Valve and Worm Shaft in Housing
G 1629-A

FIG. 24 —Installing Adjuster Plugprocarmanuals.com