Chevrolet 1977 10 Series, Repair Manual, Page: 62 / 468

3B-20 OVERHAUL MANUAL
RETAINING RING
BACK UP WASHER
OUTER SEAL
/ INNER SEAL
BACK UP WASHER
J -6 2 7 8 -2
TOP O F TO O L
FLUSH W ITH
H O U S IN G
Fig. 3 B -5 4 —In s ta llin g P itm a n S h a ft Seals (On Bench)
A dapter J-6278-2 is flush with the housing (fig. 3B-54).
c. Remove the tool and adapter, then install the outer
steel washer and seal retaining ring. The retaining ring will
not seat in the groove at this time.
d. Reinsert Tool J-6278 with A daper J-6278-2 and
continue driving the seals until the retaining ring seats in its
groove (Refer to Inset, Figure 3B-54), then remove the tool
and adapter.
Removal and Installation of Pitman Shaft Seals
with Steering Gear in Vehicle (fig. 3B-55)
If upon inspection of the gear, it is found that oil leakage
exists at the pitm an shaft seals, the seals may often be
replaced without removing the gear assembly from the
vehicle as follows:
1. Remove pitm an nut and disconnect pitm an arm from
pitm an shaft using Puller J-6632.
CAUTION: Do not hammer on the end o f Puller
Tool J-6632.
2. Thoroughly clean end of pitman shaft and gear
housing, then tape splines on end of pitm an shaft to insure
that seals will not be cut by splines during assembly.
Fig. 3B -5 5—Installing Pitman Shaft Seals
NOTE:
Only one layer of tape should be used; an
excessive am ount of tape will not allow the seals to pass
over it, due to the close tolerance between the seals and
the pitm an shaft.
3. Remove pitm an shaft seal retaining ring with Snap
Ring Pliers J-4245.
4. Start engine and turn steering wheel fully to the left
so that oil pressure in the housing can force out pitm an shaft
seals. Turn off engine.
NOTE:
Use suitable container to catch oil forced out
of gear. This m ethod of removing the pitman shaft seals
is recommended, as it eliminates the possibility of
scoring the housing while attem pting to pry seals out.
If pressure of oil does not remove seals, turn off engine,
remove the steering gear and remove the seals as
outlined previously in this section.
5. Clean the end of housing thoroughly so that dirt will
not enter housing with the installation of the new seals.
6. Lubricate the seals thoroughly with Power Steering
Fluid to install seals with Installer J-6219. Install the inner
single lip seal first, then a back-up washer. Drive seal in far
enough to provide clearance for the outer seal, back-up
washer and retaining ring. Make sure that the inner seal does
not bottom on the counterbore. Install the outer double lip
seal and the second back-up washer in only far enough to
provide clearance for the retaining ring. Install retaining ring.
7. Fill pum p reservoir to proper level. Start engine and
allow engine to idle for at least three minutes without turning
steering wheel. T urn wheel to left and check for leaks.
8. Remove tape and reconnect pitman arm.
CAUTION: The pitman arm to steering gear nut is
an important attaching part in that it could affect
the performance o f vital components and systems,
and/or could result in major repair expense. It must
be replaced with one o f the same part number or
with an equivalent part i f replacement becomes
necessary. Do not use a replacement part o f lesser
quality or substitute design. Torque values must be
used as specified during reassembly to assure proper
retention o f this part.
GEAR ASSEMBLY
1. Lubricate the worm, lower thrust bearing and the two
thrust washers with Power Steering Fluid, then install one
thrust washer, the bearing, and the other thrust washer over
the end of the worm (fig. 3B-56).
2. Lubricate the valve body teflon rings and a new stub
shaft cap "O" ring with Power Steering Fluid. Install the stub
shaft cap "O" ring in the valve body so it is seated against
the stub shaft cap. Align the N A R R O W N O TC H in the valve
body with the pin in the worm, then install the valve and stub
shaft assembly in the gear housing (fig. 3B-57). Apply
pressure to the VALVE BODY when installing. If pressure
is applied to the stub shaft during installation, the stub shaft
may be forced out of the valve body (fig. 3B-58).
NOTE:
The valve body is properly seated when the oil
return hole in the housing is entirely uncovered (fig. 3B-
59).
3. Lubricate a new adjuster plug "O" ring with Power
Steering Fluid and install in groove on adjuster plug. Place
Seal Protector J-6222 over the stub shaft, then install the
adjuster plug assembly in the housing until it seats against
the valve body (fig. 3B-60). Remove Seal Protector.
4. A djust the thrust bearing preload as follows:
a. D rain power steering fluid from gear by rotating the