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Steering Gear Unit: Reassembly

  1. Mount control valve housing in Holding Fixture (T57L-500-B) or vise, with flanged end up. Using power steering fluid, lightly lubricate inside control housing bore and Teflon rings on valve sleeve. Carefully install input shaft and valve sleeve into control housing bore.
  2. Install worm bearing race nut to housing. Tighten nut to 55-90 ft. lbs. (75-122 N.m). Install Allen head race nut set screw into control housing and tighten to 15-25 INCH lbs. (1.7- 2.8 N.m).
  3. Place piston on bench with ball guide holes facing up. See Fig 1 . Insert worm shaft into piston so first part of worm groove lines up with first hole in center of piston. Place ball guide in piston. Place 27-29 ball bearings in ball guide while turning worm counterclockwise as viewed from input end of shaft.
    Fig 1: Installing Ball Bearings Into Piston
    G95C27831Courtesy of FORD MOTOR CO.
  4. If all balls have not been fed into guide upon reaching left stop, rotate input shaft in one direction, and then reverse direction while inserting remaining balls. DO NOT  rotate input shaft more than 3 turns from left stop or balls will fall out of circuit.
  5. Secure guides in ball nut area of piston with ball guide clamp. Tighten ball guide clamp screw to 42-70 INCH lbs. (4.7-7.9 N.m). Dip new piston "O" ring in power steering fluid and install into piston groove. See Figure . Install new Teflon seal ring to piston end groove using care not to over-stretch ring.
  6. Apply petroleum jelly to Teflon seal ring on piston. Place new large "O" ring on control valve housing. Slide piston and control valve assembly into gear housing; be careful not to damage piston Teflon seal ring.
  7. Align oil passage in control valve housing with passage in gear housing. Place new small "O" ring in oil passage hole of gear housing. Loosely install housing attaching bolts and identification tag. Rotate piston so teeth are in same plane as sector shaft teeth. Tighten control valve housing-to-gear housing bolts to 30-45 ft. lbs. (41-61 N.m).
  8. Place sector shaft cover "O" ring in gear housing. Turn input shaft to center piston. Apply petroleum jelly to sector shaft journal. Install sector shaft and cover into gear housing. Install and tighten sector shaft cover bolts to 55-70 ft. lbs. (75-95 N.m). Perform steering gear meshload over-center adjustment. See STEERING GEAR MESHLOAD  under ADJUSTMENTS.
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