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Power Steering Gear: Reassembly

  1. Lubricate the sector shaft seal bore. See Figure. Use Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A.
  2. Use the Sector Shaft Seal Replacer to install the sector shaft seal. See Fig 1. Lubricate the sector shaft seal, using Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A.
    Fig 1: Installing Sector Shaft Seal
    G00126563Courtesy of FORD MOTOR CO.
  3. Install the spacer. See Figure.
  4. Install the snap ring. See Figure.
    5. NOTE: Place the steering gear sector shaft dust seal on the Sector Shaft Seal Replacer so the raised lip is toward the tool.
  5. Use the Sector Shaft Seal Replacer to install the sector shaft dust seal. See Figure. Lubricate the steering gear sector shaft dust seal; use Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A.
  6. Remove the steering gear housing from the Bench Mounted Holding Fixture.
  7. Position the input shaft bearing in the valve housing and use the Input Shaft Bearing/Seal Tool Set and a press to seat the bearing. See Fig 2.
  8. Use the Input Shaft Bearing/Seal Tool and a press to seat the power steering gear input shaft seal. See Fig 2.
    Fig 2: Seating Bearing & Input Shaft Seal Using Input Shaft Bearing/Seal Tool & Press
    G00126567Courtesy of FORD MOTOR CO.
  9. Install the input shaft snap ring. See Figure.
  10. Use the Input Shaft Bearing/Seal Tool to install the power steering gear input shaft seal dust seal. See Fig 3.
    Fig 3: Installing Input Shaft Dust Seal
    G00126570Courtesy of FORD MOTOR CO.
  11. Mount the valve housing in the Bench Mounted Holding Fixture. See Fig 4.
    Fig 4: Mounting Valve Housing In Bench Mounted Holding Fixture
    G00126571Courtesy of FORD MOTOR CO.
  12. Install the power steering gear input shaft and control into the valve housing. See Fig 5.
    Fig 5: Installing Power Steering Gear Input Shaft Into Valve Housing
    G00126572Courtesy of FORD MOTOR CO.
  13. Position the power steering gear race nut into the valve housing. See Figure.
  14. Use the Adjuster and Locknut Wrench to tighten the race nut to specification. See TORQUE SPECIFICATIONS . See Figure.
  15. Install the valve housing set screw, and tighten to specification, See TORQUE SPECIFICATIONS . See Figure.
  16. Remove the valve housing from the Bench Mounted Holding Fixture and position the piston on the worm gear. See Figure.
    Fig 6: Positioning Piston On Worm Gear
    G00126576Courtesy of FORD MOTOR CO.
    17. 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 procedure.
  17. Install the steering gear ball return guide on the piston. See Figure.
    18. WARNING: The correct number of balls are 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.
  18. 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 Figure.
  19. Install the steering gear ball return guide clamps, install the bolts and tighten to specification, See TORQUE SPECIFICATIONS .
  20. Install a new gasket. See Figure.
  21. Lubricate and install the seal on the piston. Use Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A.
    22. NOTE: Make sure to align the oil passages in the steering gear housing.
    Fig 7: Rotating Teeth For Alignment For Installation
    G00126581Courtesy of FORD MOTOR CO.
  22. Install the piston assembly into the steering gear housing. See Figure.
  23. Rotate the teeth so they are on the same plane as the steering gear sector shaft. See Fig 8
    Fig 8: Rotating Teeth For Alignment For Installation
    G00126582Courtesy of FORD MOTOR CO.
  24. Loosely install the valve housing bolts and the identification tag, if so equipped. See Fig 9.
    Fig 9: Identifying Valve Housing Bolts
    G00126583Courtesy of FORD MOTOR CO.
  25. Lubricate the O-ring on the sector shaft housing cover. See Fig 10. Use Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A.
    Fig 10: Identifying O-Ring For Lubrication
    G00126584Courtesy of FORD MOTOR CO.
  26. Rotate the housing clockwise and install the sector shaft into the sector shaft housing. See Fig 11.
    Fig 11: Installing Sector Shaft Into Sector Shaft Housing
    G00126585Courtesy of FORD MOTOR CO.
    27. NOTE: The sector shaft lock nut will be tightened during the steering gear meshload adjustment.
  27. Install the sector shaft lock nut. See Figure.
    28. NOTE: Loosely install the sector shaft housing bolts.
  28. Install the sector shaft and housing assembly. See Figure.
  29. Tighten the steering gear sector shaft housing cover bolts to specification. TORQUE SPECIFICATIONS . See Figure.
  30. Tighten the bolts to specification. TORQUE SPECIFICATIONS .
  31. Install steering gear in vehicle. Perform meshload adjustment. See STEERING GEAR MESHLOAD ADJUSTMENT  under ADJUSTMENTS & INSPECTION.
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