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Power Steering Gear: Reassembly

  1. Lubricate the sector shaft seal bore using Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specification ESB-M1C93-A.
  2. Use Sector Shaft Seal Replacer to install the sector shaft seal. Lubricate the sector shaft seal, using Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specification ESB-M1C93-A. See Fig 1 .
    Fig 1: Installing Sector Shaft Seal
    G00126563Courtesy of FORD MOTOR CO.
  3. Install the spacer. See Fig 2 .
    Fig 2: Identifying Spacer
    G00126564Courtesy of FORD MOTOR CO.
  4. Install the snap ring. See Figure .
    5. NOTE: Place the steering gear sector shaft housing oil seal on Sector Shaft Seal Replacer so the raised lip is toward the tool.
  5. Use Sector Shaft Seal Replacer to install the steering gear sector shaft housing oil seal. Lubricate the steering gear sector shaft housing oil seal, using Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specification ESB-M1C93-A. See Fig 1 .
  6. Position the input shaft bearing in the valve housing and use Input Shaft Bearing Seal Tool Set and a press to seat the bearing. See Fig 3 .
  7. Use Input Shaft Bearing Seal Tool Set and a press to seat the input shaft seal.
    Fig 3: Seating Input Shaft Bearing
    G00126567Courtesy of FORD MOTOR CO.
  8. Install the input shaft snap ring. See Figure .
  9. Use input Shaft Bearing Seal Tool Set to install the input shaft dust seal. See .
    Fig 4: Seating Input Shaft Dust Seal
    G00126570Courtesy of FORD MOTOR CO.
  10. Mount the valve housing in Bench Mounted Holding Fixture. See Fig 5 .
    Fig 5: Mounting Valve Housing In Bench Mounted Holding Fixture
    G00126571Courtesy of FORD MOTOR CO.
  11. Install the input shaft into the valve housing. See Fig 6 .
    Fig 6: Installing Input Shaft Valve Housing
    G00126572Courtesy of FORD MOTOR CO.
  12. Position the power steering gear race nut into the valve housing. See Figure .
  13. Use Adjuster and Lock nut Wrench to tighten the power steering gear race nut to specification. See TORQUE SPECIFICATIONS  .
  14. Install the steering gear Allen head race lock nut to specification. See TORQUE SPECIFICATIONS  . See Figure .
  15. Remove the valve housing from the Bench Mounted Holding Fixture and position the piston on the input shaft valve. See Figure .
    16. WARNING: Hold the ball return guides until the cap or clip is reinstalled. Failure to hold the guides will result in a trapped ball or balls, which can cause a vehicle accident. If the ball guides become unseated at any time, remove all the balls and repeat the procudure.
  16. Install the steering ball return guide on the piston.
    17. WARNING: The correct number of balls is required for proper gear operation. Count the balls and insert each carefully. To make sure the balls are properly installed, rotate the steering gear input worm gear and rack from one end of travel to the other without allowing the poppet adjuster to contact the valve housing or moving the valve housing pilot face more than 69.1 MM (2-3/4 INCHES) from the input end of the rack piston. If the steering gear input worm gear and rack cannot be rotated, reinstall the balls. If a steering gear is installed with a steering gear input worm gear and rack that cannot rotate, the steering gear will not function correctly and steering and gear failure can result.
    Fig 7: Locating Steering Gear Ball Return Guide & Piston
    G00126577Courtesy of FORD MOTOR CO.
  17. Rotate the piston while holding the steering gear ball return guide and install the 28 ball bearings into the opening in the ball guide. See Fig 7 .
  18. Position the ball guide clamp. Install the two ball guide clamp bolts. See Fig 8 . Tighten the clamp bolts to specification. See TORQUE SPECIFICATIONS  .
    Fig 8: Installing Ball Guide Clamp
    G00126579Courtesy of FORD MOTOR CO.
  19. Lubricate and install the piston seal on the piston, then install a new gasket on the valve housing. Use Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specification ESB-M1C93-A. See Figure .
    20. NOTE: Make sure to align the oil passages in the gear housing.
    Fig 9: Installing Piston Assembly Into Gear Housing
    G00126581Courtesy of FORD MOTOR CO.
  20. Install the piston assembly into the gear housing. See Fig 9 .
  21. Rotate the teeth so they are on the same plane as the sector shaft.See Fig 10 .
    Fig 10: Aligning Gear Teeth
    G00126582Courtesy of FORD MOTOR CO.
  22. Loosely install the four valve housing bolts. If so equipped, install the identification tag. See Fig 11 .
    Fig 11: Identifying Valve Housing Bolts
    G00126583Courtesy of FORD MOTOR CO.
  23. Lubricate the O-ring on the sector shaft housing cover. Use Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specification ESB-M1C93-A.
    Fig 12: Identifying Sector Shaft Housing Cover O-Ring
    G00126584Courtesy of FORD MOTOR CO.
  24. Rotate the housing clockwise and install the sector shaft into sector shaft housing.
    Fig 13: Installing Sector Shaft Into Sector Shaft Housing
    G00126585Courtesy of FORD MOTOR CO.
    25. NOTE: The sector shaft lock nut will be tightened during steering gear meshload adjustment.
  25. Install the sector shaft lock nut. See Figure
    26. NOTE: Loosely install the sector shaft housing bolts.
  26. Install the sector shaft housing assembly. See Figure .
  27. Tighten the four sector shaft housing bolts to specification. See TORQUE SPECIFICATIONS  .
  28. Tighten the four valve housing bolts to specification. See TORQUE SPECIFICATIONS  .
  29. Install the power steering gear. See POWER STEERING GEAR  under REMOVAL & INSTALLATION. Adjust steering gear meshload. See STEERING GEAR MESHLOAD ADJUSTMENT  under ADJUSTMENTS & INSPECTION.
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