Hey guys. I just got done doing this and i figured before i did it that i'd take pics of the process and do a write-up, because i know there are alot of people who would like to lose the power steering
I did all this with basic hand tools (aside from the 1¼ wrench, but when you maintain a tractor trailer that becomes a basic tool.) This can be done several different ways, i'm not going to get into it too extensively. IMO the easiest way is to pull the engine. You won't need to remove the outer tie rods from the ball joints or anything. Here's how i did mine:
Tools list:
I do not have pictures for the steering rack removal.
Lets begin:
Removing the steering rack
Now onto the juicy part, de-powering the steering rack!
Re-assembly
This is almost exactly reverse of Un-assembly. There are two exceptions:
Voila! One Manual steering rack
http://tinypic.com/m/9t0q6h/4
ADDED: 2ndgengt did a recent how-to on installing a ribbed pulley for the belt tensioner, This is an excellent write up IMO.
You can see it here: http://forums.probetalk.com/showpost...51&postcount=1
I did all this with basic hand tools (aside from the 1¼ wrench, but when you maintain a tractor trailer that becomes a basic tool.) This can be done several different ways, i'm not going to get into it too extensively. IMO the easiest way is to pull the engine. You won't need to remove the outer tie rods from the ball joints or anything. Here's how i did mine:
Tools list:
- vice grips and a flathead screwdriver
- 1¼ open end wrench
- 13mm open end or line wrench
- 3/8 dr. ratchet
- 8" 3/8 dr. extension
- 3/8 dr.12mm socket
- 3/8 dr.14mm socket
- 3/8 dr.15mm socket
- Chisel/Flathead screwdriver
- small center punch
- Hammer
- Large deepwell socket or seal driver
I do not have pictures for the steering rack removal.
Lets begin:
Removing the steering rack
- You'll need a pair of vice grips and a flathead screwdriver, as well as a 1¼ open end wrench
- Remove the bellow's boot (inner tie rod boot). To do this you'll need to loosen the clamp on the tie rod itself with a pair of vice grips, slide it down off the boot. For the inner one simply put a flathead screwdriver between it and the boot and pry it off. it snaps apart easily.
- For the driver's side, turn your steering wheel to the right about half way, slide the boot off the steering rack. and down the inner tie rod (you will need to rotate the boot to do this.)
- Once its slid down the boot you will see where the inner tie rod connects to the steering rack. slide your 1¼ wrench on the square and break it loose. Turn it loose until it angles itself and the threads come out of the steering rack.
- Now for the passenger side, turn your steering wheel to the left, half way from center just like you did, and repeat the tie rod removal. now turn your steering wheel back to the center.
- Looking at the steering rack, there are 2 14mm bolts, and 2 14mm nuts. Remove the bottom (bolts) first. To do this you will need to loosen the square plate that is blocking the drivers side one. take your 12mm socket and loosen the bolt in the center. Rotate the plate out of the way (or remove it)
- Take your 14mm socket and an extension and break the bolts loose, and sit them nearby. Now you'll remove the clamps holding the lines to the subframe. There is one in the middle, and one on the passenger side. take your 10mm socket and extension and remove the bolts. Now we remove the 2 nuts. Remove them and sit them nearby.
- Pull your steering rack off the 2 studs coming out of the subframe, it won't fall completely do the ground just yet.
- Pull up the boot that covers the steering column, and remove the TOP section of the U joint from the steering column. Remove the 12mm bolt and it will slide off. Now your steering rack is removed from your car
- http://i43.tinypic.com/x21h0y.jpg
Now onto the juicy part, de-powering the steering rack!
- Set the rack on your workbench/etc.
http://i42.tinypic.com/2nti8h0.jpg
- remove all 4 lines from it. the larger ones are 17mm, and the smaller ones are 13mm. My 17mm ones would not come out so i just cut the lines where they went in and tossed them aside.
http://i40.tinypic.com/21alk44.jpg
http://i41.tinypic.com/148ot53.jpg
- Put the rack in a vice or something to hold it in place
http://i40.tinypic.com/95yepu.jpg
- Remove the adjusting cover. Start by undoing the large locknut, then the cover, spring and support yoke. For me i broke the locknut loose with a monkey wrench and the cover came with it.
http://tinypic.com/m/9t0m69/4
http://tinypic.com/m/9t0pwg/4
http://tinypic.com/m/9t0pwi/4
- On the top of the input shaft there will be a snap ring, remove this and set it nearby
http://tinypic.com/m/9t0pyr/4
- Now You'll want to remove the cover on the bottom of the pinion shaft. This is plastic for some reason so what i did was put a chisel in one of the notches and tapped it around with a hammer until it spun loose
http://tinypic.com/m/9t0pw8/4
- It reveals this: A 15mm nut. Remove it and set it nearby
http://tinypic.com/m/9t0pw9/4
- tap the bottom of the pinion shaft (where you just removed the nut) with a small punch, it will move the steering shaft to the side (this is fine) and will pop out. set it off to the side out of harm's way
http://tinypic.com/m/9t0pys/4
- Now onto removing the shaft itself (and what makes it power steering.) On the opposite end of the steering shaft there will be a "nut" type thing with 2 notches on it.
http://tinypic.com/m/9t0pwj/4
- Tap this around with a flat head screwdriver or chisel until you see the stop ring pop out through the oval hole, Now tap the nut back the opposite direction and it will pull the stop ring out
http://i43.tinypic.com/kegn49.jpg
- pull the stop ring out of the hole in the nut and set it nearby.
- Tap the opposite side of the steering shaft with a hammer and it will pop out the side that had the stop ring nut on it.
http://tinypic.com/m/9t0pyt/4
- pull it out and set it somewhere on your bench, preferably a clean place or on paper towels like i did
http://tinypic.com/m/9t0pyu/4
- See that large cylinder on the steering shaft? that is what gives it power steering
- Carefully cut the seal from the shaft. I used a grinder to cut most of the way through the seal and then whacked it with a chisel. No damage to the shaft.
BE CAREFUL with the stop ring that is on there because it is needed!
http://tinypic.com/m/9t0sol/4
http://tinypic.com/m/9t0pyv/4
- time for some lube! I just used a tube of grease that i use to grease parts on tractor trailers
http://tinypic.com/m/9t0q69/4
- dip the steering shaft in the tube and smear the grease around on it. don't put it on too thick otherwise it will make a mess when you reinstall the shaft.
Re-assembly
This is almost exactly reverse of Un-assembly. There are two exceptions:
- The seal on top of the pinion shaft needs to be seated. I used a large deepwell socket and a hammer.
http://tinypic.com/m/9t0q6c/4
- Reinstall your fittings and either fill them with JB weld, or weld them shut (it doesnt hold pressure, just keeps dirt/etc out)
http://tinypic.com/m/9t0q6f/4
Voila! One Manual steering rack
http://tinypic.com/m/9t0q6h/4
ADDED: 2ndgengt did a recent how-to on installing a ribbed pulley for the belt tensioner, This is an excellent write up IMO.
You can see it here: http://forums.probetalk.com/showpost...51&postcount=1
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