Dodge Dakota (R1). Manual — part 586
(5) Insert Arbor C-4175 into bore of rack piston
(Fig. 16) and hold tool tightly against worm shaft.
(6) Turn the stub shaft with a 12 point socket
COUNTERCLOCKWISE, this will force the rack pis-
ton onto the tool and hold the rack piston balls in
place.
(7) Remove the rack piston and tool together from
housing.
(8) Remove tool from rack piston.
(9) Remove rack piston balls.
(10) Remove clamp bolts, clamp and ball guide
(Fig. 17).
(11) Remove teflon ring and O-ring from the rack
piston (Fig. 18).
(12) Remove the adjuster lock nut and adjuster
nut from the stub shaft.
(13) Pull the stub shaft with the spool valve and
thrust support assembly out of the housing.
(14) Remove the worm shaft from the housing
(Fig. 19).
INSTALLATION
NOTE: Clean and dry all components and lubricate
with power steering fluid.
(1) Check for scores, nicks or burrs on the rack
piston finished surface. Slight wear is normal on the
worm gear surfaces.
(2) Install O-ring and teflon ring on the rack pis-
ton.
(3) Install worm shaft in the rack piston and align
worm shaft spiral groove with rack piston ball guide
hole (Fig. 20).
CAUTION: The rack piston balls must be installed
alternately into the rack piston and ball guide. This
maintains worm shaft preload. There are 12 black
balls and 12 silver (Chrome) balls. The black balls
are smaller than the silver balls.
Fig. 16 Rack Piston with Arbor
1 - RACK PISTON
2 - SPECIAL TOOL C-4175
Fig. 17 Rack Piston
1 - CLAMP
2 - BALLS
3 - RACK PISTON
4 - BALL GUIDE
Fig. 18 Rack Piston Teflon Ring and O-Ring
1 - TEFLON SEAL
2 - BACK-UP O-RING MUST BE INSTALLED UNDER PISTON
RING
3 - RACK PISTON NUT
19a - 6
STEERING
R1
WORM SHAFT (Continued)
(4) Lubricate and install rack piston balls through
return guide hole while turning worm shaft COUN-
TERCLOCKWISE (Fig. 20).
(5) Install remaining balls in guide using grease to
hold the balls in place (Fig. 21).
(6) Install the guide onto rack piston and install
clamp and clamp bolts. Tighten bolts to 58 N·m (43
ft. lbs.).
(7) Insert Arbor C-4175 into bore of rack piston
and hold tool tightly against worm shaft.
(8) Turn the worm shaft COUNTERCLOCKWISE
while pushing on the arbor. This will force the rack
piston onto the arbor and hold the rack piston balls
in place.
(9) Install the races and thrust bearing on the
worm shaft and install shaft in the housing (Fig. 19).
(10) Install the stub shaft with spool valve, thrust
support assembly and adjuster nut in the housing.
(11) Install the rack piston and arbor tool into the
housing.
(12) Hold arbor tightly against worm shaft and
turn stub shaft CLOCKWISE until rack piston is
seated on worm shaft.
(13) Install pitman shaft and side cover in the
housing.
(14) Install rack piston plug and tighten to 150
N·m (111 ft. lbs.).
(15) Install housing end plug.
(16) Adjust worm shaft thrust bearing preload and
over-center rotating torque.
PITMAN BEARING
REMOVAL
(1) Clean exposed end of pitman shaft and housing
with a wire brush.
(2) Remove preload adjuster nut (Fig. 22).
(3) Rotate the stub shaft with a 12 point socket
from stop to stop and count the number of turns.
(4) Center the stub shaft by rotating it from the
stop 1/2 of the total amount of turns.
Fig. 19 Worm Shaft
1 - GEAR HOUSING
2 - BEARING RACE
3 - WORM SHAFT
4 - BEARING
Fig. 20 Installing Balls in Rack Piston
1 - INSTALL BALLS IN THIS HOLE WHILE SLOWLY ROTATING
WORM COUNTER CLOCKWISE
2 - WORM FLANGE
Fig. 21 Balls in the Return Guide
1 - GUIDE
2 - PETROLEUM JELLY
3 - BALLS
R1
STEERING
19a - 7
WORM SHAFT (Continued)
(5) Remove side cover bolts and remove side cover,
gasket and pitman shaft as an assembly (Fig. 22).
NOTE: The pitman shaft will not clear the housing if
it is not centered.
(6) Remove pitman shaft from the side cover.
(7) Remove dust seal from the housing with a seal
pick (Fig. 23).
CAUTION: Use care not to score the housing bore
when prying out seals and washer.
(8) Remove retaining ring with snap ring pliers.
(9) Remove washer from the housing.
(10) Remove oil seal from the housing with a seal
pick.
(11) Remove pitman shaft bearing from housing
with a bearing driver and handle (Fig. 24).
INSTALLATION
(1) Install pitman shaft bearing into housing with
a bearing driver and handle.
(2) Coat the oil seal and washer with special
grease supplied with the new seal.
(3) Install the oil seal with a driver and handle.
(4) Install backup washer.
(5) Install the retainer ring with snap ring pliers.
(6) Coat the dust seal with special grease sup-
plied with the new seal.
Fig. 22 Side Cover and Pitman Shaft
1 - SIDE COVER BOLTS
2 - PRELOAD ADJUSTER NUT
3 - SIDE COVER
4 - GASKET SEAL
5 - PITMAN SHAFT GEAR
6 - HOUSING ASSEMBLY
Fig. 23 Pitman Shaft Seals & Bearing
1 - BEARING
2 - WASHER
3 - DUST SEAL
4 - RETAINER
5 - OIL SEAL
Fig. 24 Needle Bearing Removal
1 - REMOVER
2 - SIDE COVER AREA
19a - 8
STEERING
R1
PITMAN BEARING (Continued)
(7) Install dust seal with a driver and handle.
(8) Install pitman shaft to side cover by screwing
shaft in until it fully seats to side cover.
(9) Install preload adjuster nut. Do not tighten
nut until after Over-Center Rotation Torque
adjustment has been made.
(10) Install gasket to side cover and bend tabs
around edges of side cover (Fig. 4).
(11) Install pitman shaft assembly and side cover
to housing.
(12) Install side cover bolts and tighten to 60 N·m
(44 ft. lbs.).
(13) Perform over-center rotation torque adjust-
ment.
PITMAN SHAFT SEAL
REMOVAL
(1) Clean exposed end of pitman shaft and housing
with a wire brush.
(2) Remove preload adjuster nut (Fig. 25).
(3) Rotate the stub shaft with a 12 point socket
from stop to stop and count the number of turns.
(4) Center the stub shaft by rotating it from the
stop 1/2 of the total amount of turns.
(5) Remove side cover bolts and remove side cover,
gasket and pitman shaft as an assembly (Fig. 25).
NOTE: The pitman shaft will not clear the housing if
it is not centered.
(6) Remove pitman shaft from the side cover.
(7) Remove dust seal from the housing with a seal
pick (Fig. 26).
CAUTION: Use care not to score the housing bore
when prying out seals and washer.
(8) Remove retaining ring with snap ring pliers.
(9) Remove washer from the housing.
(10) Remove oil seal from the housing with a seal
pick.
(11) Remove pitman shaft bearing from housing
with a bearing driver and handle (Fig. 27).
INSTALLATION
(1) Install pitman shaft bearing into housing with
a bearing driver and handle.
(2) Coat the oil seal and washer with special
grease supplied with the new seal.
(3) Install the oil seal with a driver and handle.
(4) Install backup washer.
(5) Install the retainer ring with snap ring pliers.
(6) Coat the dust seal with special grease sup-
plied with the new seal.
(7) Install dust seal with a driver and handle.
(8) Install pitman shaft to side cover by screwing
shaft in until it fully seats to side cover.
Fig. 25 Side Cover and Pitman Shaft
1 - SIDE COVER BOLTS
2 - PRELOAD ADJUSTER NUT
3 - SIDE COVER
4 - GASKET SEAL
5 - PITMAN SHAFT GEAR
6 - HOUSING ASSEMBLY
Fig. 26 Pitman Shaft Seals & Bearing
1 - BEARING
2 - WASHER
3 - DUST SEAL
4 - RETAINER
5 - OIL SEAL
R1
STEERING
19a - 9
PITMAN BEARING (Continued)
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