Rack Yoke Plug Clearance
See Figure 1
The rack yoke plug clearance adjustment is not a normal service adjustment. It is only required when the input shaft and valve assembly is removed.
- Clean the exterior of the steering rack thoroughly.
- Install two long bolts and washers through the bushings and attach the rack to a bench mounted holding fixture T57L-500-B or equivalent.
- Do not remove the external pressure lines, unless they are leaking or damaged. If the lines are removed, install new seals. If the lines are damaged, they must be replaced.
- Drain the power steering fluid by rotating the input shaft lock-to-lock twice using pinion shaft torque adapter tool T74P-3504-R or equivalent. Cover the ports on the valve housing with a shop cloth while draining the gear to avoid possible oil spray.
- Insert an inch pound torque wrench with a maximum capacity of 30-60 inch lbs. (3.4-6.8 Nm) into the pinion shaft torque adapter tool. Position the adapter and wrench on the input shaft splines.
- Loosen the yoke plug locknut with pinion housing locknut wrench T78P-3504-H or equivalent. Loosen the yoke plug with a 3 / 4 in. socket wrench.
- With the rack at the center of travel, tighten the yoke plug to 45-50 inch lbs. (5.0-5.6 Nm). Clean the threads of the yoke plug prior to tightening to prevent a false reading.
- Back off the yoke plug approximately 1 / 8 turn, 44 degrees minimum to 54 degrees maximum until the torque required to initiate and sustain rotation of the input shaft is 7-18 inch lbs. (0.8-2.0 Nm) for base power steering or 7-24 inch lbs. (0.8-3.0 Nm) for handling package.
- Place pinion housing yoke locknut wrench T78P-3504-H or equivalent, on the yoke plug locknut. While holding the yoke plug, tighten the locknut to 44-66 ft. lbs. (60-89 Nm).
Do not allow the yoke plug to move while tightening or the preload will be affected.
- Install the steering rack in the vehicle.
REMOVAL & INSTALLATION
- Disconnect the negative battery cable. Turn the ignition switch to the RUN position.
- Raise and support the vehicle safely using jackstands. Position a drain pan to catch the fluid from the power steering lines.
- Remove the one bolt retaining the flexible coupling to the input shaft.
- Remove the front wheel and tire assemblies. Remove the cotter pins and nuts from the tie rod ends and separate the tie rod studs from the spindles.
- Remove the two nuts, insulator washers and bolts retaining the steering rack to the crossmember. Remove the front rubber insulators.
- Position the rack to allow access to the hydraulic lines and disconnect the lines.
- Remove the steering rack.
- Install new plastic seals on the hydraulic line fittings.
- Install the rack on the mounting spikes and install the hydraulic lines. Tighten the fittings to 10-15 ft. lbs. (14-20 Nm) on 1989 vehicles and 20-25 ft. lbs. (27-33 Nm) on 1990-93 vehicles.
The hoses are designed to swivel when properly tightened. Do not attempt to eliminate looseness by over-tightening the fittings.
- Install the front rubber insulators. Make sure all rubber insulators are pushed completely inside the gear housing before installing the mounting bolts.
- Insert the input shaft into the flexible coupling. Install the mounting bolts, insulator washers and nuts. Tighten the nuts to 30-40 ft. lbs. (41-54 Nm) while holding the bolts. Install and tighten the flexible coupling bolt to 20-30 ft. lbs. (28-40 Nm).
- Connect the tie rod ends to the spindle arms and install the retaining nuts. Tighten to 35-47 ft. lbs. (48-63 Nm). After tightening, tighten the nuts to their nearest cotter pin castellation and install new cotter pins.
- Remove the jackstands and carefully lower the vehicle.
- Turn the ignition switch to OFF and connect the negative battery cable.
- Fill the power steering system with the proper type and quantity of fluid.
- If the tie rod ends were loosened, check and adjust the front end alignment.