GMC 1976 ZEO 6083 Maintenance Manual page 557

NOTE : If mounting threads are stripped, do not
repair . Replace housing .
STEERING GEAR OVERHAUL
Disassembly of the major components within the
gear must be performed on a clean work bench. The
work area, tools, and parts must be kept clean at all
times. Refer to Figures 24 and 25 for parts nomencla-
ture and location .
NOTE : Most service kits are purposely designed
to replace not only a worn part, but also adjacent
parts which should be replaced at the same time .
To ensure an effective repair, use all parts sup-
plied in the kit.
STEERING GEAR DISASSEMBLY
1 . Rotate end cover retainer ring so that one end
of the ring is over the hole in the side of the housing.
Force the end of the ring from its groove and remove
ring (figure 26).
2. Turn the coupling flange counter-clockwise
until the rack-piston just forces end cover out of
housing. Remove cover and discard "O" ring .
CAUTION :
Do not turn stub shaft any fur-
ther than absolutely necessary to remove
the end plug, or balls from rack-piston and
worm circuit may escape and lay loose in-
side the rackpiston chamber.
3 . Remove the rack-piston end plug as shown in
Figure 27 .
Figure 26-Removing End Cover
STEERING 9 .25
Figure 27-Removing Rack-Piston End Plug
NOTE:
To aid in loosening the aluminum end
plug (female square drive) strike sharply using
1 " or larger diameter brass drift and hammer.
4. Remove the pitman shaft and side cover as
follows:
a. Loosen the over-center adjusting screw
locknut and remove the four side cover attaching
bolts.
b. Rotate the side cover until the rack-piston
and pitman shaft teeth are visible, then turn the cou-
pling flange until the pitman shaft teeth are centered
in the housing opening. Tap the pitman shaft with a
soft hammer and remove the pitman shaft and side
cover from the housing. Remove the side cover "O"
ring and discard. If gasket seal is used, inspect, dis-
card only if damaged.
5 . Remove the rack-piston as follows :
a. Insert Ball Retainer Tool J-21552 into the
rack-piston bore with pilot of tool seated in the end
of the worm (figure 28). Turn stub shaft counter
clockwise while holding tool tightly against worm .
The rack-piston will be forced onto the tool . Hold
tool and pull rack-piston farther onto tool to prevent
end circuit balls from falling out.
b. Remove the rack-piston with Ball Retainer
Tool J-21552 from gear housing.
6 . Remove the adjuster plug as follows:
a. Loosen the adjuster plug locknut and
remove .
b. Remove adjuster plug assembly with Span-
ner Wrench J-7624 (figure 29). Remove and discard
the adjuster plug "O" ring .