TECHNICAL SERVICE

RACK and PINION NATIONWIDE 1-800-521-8510

ARIZONA 623-842-4047 X 112
INSTALLATION INSTRUCTIONS PART #’S: MULTIPLE PART NUMBERS

DOCUMENT #: 220007 Rev 02 APPLICATION(S): ALL RACK and PINIONS

Page: 1 of 2

Please read all instructions before attempting to install this rack & pinion unit.

This unit has been 100% inspected and tested to insure long leak proof operation.
No core credit will be given for non-rebuildable cores.

Particle contaminated fluid is the number one cause of premature failure. Before
installing this unit be sure to completely flush the pump and all hoses, see instructions on
reverse side. The warranty on this unit is void if this unit is returned with contaminated
fluid.

The O-rings and Teflon seals on the hose fittings must be replaced to insure leak free
installation. The correct seals for your style of fitting must be used. Be careful not to over
torque the hose fittings this may cause damage to the threads and the housing. The Ford
swivel type fitting uses two seals, one O-ring type and one Teflon type. Never torque this
type of fitting more than 15ft. lbs. Damage to threads or housing will void the warranty.

Unserviceable internal seal Ford Teflon & O-ring Fitting GM Hose Fitting

Honda, Acura and Sterling vehicles all require Honda power steering fluid. Honda
power steering fluid must be used in these applications or the warranty is void. Honda
Part #08208-99961. Hose End

Most of the Chrysler units use two different size mounting

bolts. The housing on the remanufactured unit has been machined
for larger bolts. If the mounting bolts you have fit loose in the
housing, you need to use the bushings that are supplied. Fit the
correct bushing to the mounting bolts and push the bushing into
the corresponding mounting hole. If the rack is mounted loose,
handling, noise, and vibration problems may occur.

Some Ford units use a small pressure relief valve in the pressure
port. This valve is not supplied with the unit. Before installing the
rack and pinion transfer the valve from the pressure port of the old
unit to the new unit. To insure proper operation install the spring Pressure Relief Valve
side of the valve into the pressure port. Ford Part # E8DZ-3N603A
 TECHNICAL SERVICE
RACK and PINION NATIONWIDE 1-800-521-8510
ARIZONA 623-842-4047 X 112
INSTALLATION INSTRUCTIONS PART #’S: MULTIPLE PART NUMBERS

DOCUMENT #: 220007 Rev 02 APPLICATION(S): ALL RACK and PINIONS

Page: 2 of 2

Caution: Flush system only with approved power steering fluid. Never use solvents or
parts cleaner to flush system because seals and O-Rings will swell or deteriorate.
How to Flush:
1. If the rack and pinion, pump and hoses are being replaced at the same time, it is not
necessary to flush the system. Otherwise, follow the procedure below.
2. Disable engine from starting.
3. When only replacing the rack and pinion and not the pump, do not attach the hoses to
the rack and pinion prior to flushing the system.
4. Disconnect the return hose from the pump and cap the reservoir return pipe.
5. Place the pressure hose into a suitable waste container such as an oil pan or bucket.
6. Fill the reservoir with power steering fluid.
7. Turn the engine over several times until the fluid being discharged from the pressure
hose is free of contamination. Do not allow the pump to run out of fluid.
8. After the system is flushed, properly connect all hose fittings.
How to Bleed:
1. Raise the front wheels off the ground.
2. Turn the steering wheel to the full left lock.
3. Fill the pump reservoir to the “full Cold” level with new fluid. Leave cap off.
4. Turn steering wheel from full left lock to full right lock and back at least 20 times with
engine off. Trapped air may cause fluid to overflow.
5. While turning wheel have an assistant check fluid level.
6. Start engine, be sure to maintain proper fluid level, reinstall cap.
7. Turn steering wheel from lock to lock at least 20 more times. Do not hold steering
wheel at lock for more than three seconds.
8. Lower front wheels to the ground.
9. Turn the steering wheel in both directions and verify: Smooth power assist; Noiseless
operation; Proper fluid level’ No system leaks; and proper fluid condition.
10. If any problem remains, see “Special Conditions”.
Special conditions:
Fluid- Foam or bubbles in fluid
Fluid must be completely free of bubbles. Periodic Bubbles could indicate a loose
connection or leaky O-ring seal in either the return hose or pressure hose. Discolored fluid
(milky, opaque, or tan color) switch ignition off, wait two minutes. Recheck hose
connections. Repeat steps 4-9 from section above. If condition still exists, replace and
check; the return hose clamps and o-rings; the pressure hose o-rings; and the rack
cylinder line o-rings.
Noise-Pump whines or groans
With engine running, recheck hoses for possible contact with frame, body, or engine. If
no contact is found, follow either method below to cool down the fluid.
Method 1: Normal Cool Down
Switch engine off. Wait for system to cool.
Method 2: Partial Fluid Replacement
Switch engine off. Use a suction device to remove fluid from reservoir. Refill with cool,
Clean fluid.