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Steering Gear: Assembly

WARNING: This page is about a different car, the 2008 Ford RV Cutaway, 2008 Ford Econoline, 2008 Ford E450 Super Duty, and 2008 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
  1. Lubricate the sector shaft seal bore with multi-purpose grease.
    2. NOTE: Lubricate the sector shaft seal and spacer with multi-purpose grease.
  2. Position the new sector shaft seal and the spacer on the special tool and install the new sector shaft seal and the spacer.
    • Install the seal and spacer until the spacer is slightly below the snap ring groove.
    3. Fig 1: Installing Sector Shaft Dust Seal
    GF0012592Courtesy of FORD MOTOR CO.
  3. Install the new sector shaft seal snap ring.
    4. Fig 2: Installing Sector Shaft Seal Snap Ring
    GF0007769Courtesy of FORD MOTOR CO.
    NOTE: Place the sector shaft dust seal on the special tool so the raised lip is toward the tool.
  4. Using the special tool, install the new sector shaft dust seal.
    • Lubricate the steering gear sector shaft dust seal with multi-purpose grease.
    5. Fig 3: Installing Sector Shaft Dust Seal
    GF0012592Courtesy of FORD MOTOR CO.
  5. Position the input shaft bearing in the valve housing.
    • Using a suitable press and the special tool, seat the bearing.
    6. Fig 4: Pressing Input Shaft Seal
    GF0007770Courtesy of FORD MOTOR CO.
  6. Using the press and the special tool, install the new input shaft seal.
    7. Fig 5: Pressing Input Shaft Seal
    GF0007770Courtesy of FORD MOTOR CO.
  7. Install the new input shaft housing snap ring.
    • Lubricate the top of the input shaft seal with multi-pupose grease.
    8. Fig 6: Identifying Input Shaft Housing Snap Ring
    GF0007771Courtesy of FORD MOTOR CO.
    NOTE: Place the input shaft dust seal on the special tool so the raised lip is toward the tool.
  8. Using the special tool, install the new input shaft dust seal.
    9. Fig 7: Installing Input Shaft Dust Seal Using Special Tool
    GF0007772Courtesy of FORD MOTOR CO.
  9. Mount the valve housing to the special tool.
    10. Fig 8: Mounting Valve Housing To Special Tool
    GF0007773Courtesy of FORD MOTOR CO.
  10. Install the input shaft and control into the valve housing.
    11. Fig 9: Input Shaft And Control
    GF0007760Courtesy of FORD MOTOR CO.
  11. Position the steering gear worm thrust bearing retainer ring into the valve housing.
    12. Fig 10: Positioning Steering Gear Worm Thrust Bearing Retainer Ring
    GF0007774Courtesy of FORD MOTOR CO.
  12. Using the special tool, tighten the worm thrust bearing retainer ring.
    • Tighten to 99 Nm (73 lb-ft).
    13. Fig 11: Worm Thrust Bearing Retainer Ring
    GF0007759Courtesy of FORD MOTOR CO.
  13. Install the new worm thrust bearing retainer ring setscrew.
    • Tighten to 2 Nm (18 lb-in).
    14. Fig 12: Identifying Worm Thrust Bearing Retainer Ring Setscrew
    GF0007758Courtesy of FORD MOTOR CO.
  14. Secure the steering gear housing in the soft-jawed vice.
  15. Install the new valve housing-to-gear housing O-ring seal.
    16. Fig 13: Identifying Valve Housing-To-Gear Housing O-Ring Seal
    GF0007767Courtesy of FORD MOTOR CO.
  16. Install the new valve housing seal.
    17. Fig 14: Identifying Valve Housing Seal
    GF0007757Courtesy of FORD MOTOR CO.
  17. Lubricate the piston seal with multi-purpose grease.
    18. Fig 15: Lubricating Piston Seal
    GF0007775Courtesy of FORD MOTOR CO.
  18. Install the piston assembly into the steering gear housing.
    19. Fig 16: Valve Housing And Piston Assembly
    GF0007756Courtesy of FORD MOTOR CO.
  19. Rotate the input shaft from stop-to-stop and record the number of rotations.
    • Rotate the input shaft 1/2 of the total rotations to align the piston for correct sector shaft installation.
    20. Fig 17: Rotating Input Shaft From Stop-To-Stop
    GF0007776Courtesy of FORD MOTOR CO.
  20. Install the sector shaft into the steering gear housing.
    21. Fig 18: Installing Sector Shaft Into Steering Gear Housing
    GF0007777Courtesy of FORD MOTOR CO.
  21. Apply threadlock and install the 4 valve housing bolts.
    • Tighten to 51 Nm (38 lb-ft).
    22. Fig 19: Identifying Valve Housing Bolts
    GF0007755Courtesy of FORD MOTOR CO.
  22. Install a new O-ring on the sector shaft housing cover and lubricate with multi-purpose grease.
    23. Fig 20: Identifying Sector Shaft Housing Cover Seal
    GF0007753Courtesy of FORD MOTOR CO.
  23. Place the sector shaft housing cover on the meshload adjusting screw and rotate the adjusting screw counterclockwise until the sector shaft housing cover is drawn into the steering gear housing and the adjusting screw bottoms out.
    24. Fig 21: Rotating Meshload Adjusting Screw Clockwise
    GF0007752Courtesy of FORD MOTOR CO.
  24. Using a soft mallet, gently tap on the meshload adjusting screw to fully seat the sector shaft housing.
  25. Apply threadlock and loosely install the 4 sector shaft housing cover bolts.
    26. Fig 22: Identifying Steering Gear Sector Shaft Housing Cover Bolts
    GF0007751Courtesy of FORD MOTOR CO.
    CAUTION: Do not exceed 31 Nm (23 lb-ft) when applying pressure to the sector shaft housing, or damage to the housing may occur.
  26. Install an original steering gear mounting bolt into the steering gear housing, applying pressure to the side of the sector shaft housing.
    • Tighten the steering gear mounting bolt to 25 Nm (18 lb-ft).
    27. Fig 23: Identifying Steering Gear Mounting Bolt
    GF0007778Courtesy of FORD MOTOR CO.
  27. Tighten the 4 sector shaft housing cover bolts to 68 Nm (50 lb-ft).
    • Remove the steering gear mounting bolt.
    28. Fig 24: Identifying Sector Shaft Housing Cover Bolts
    GF0007779Courtesy of FORD MOTOR CO.
    CAUTION: A new meshload adjusting screw lock nut must be installed or a fluid leak at the meshload adjusting screw may occur.
    NOTE: The meshload adjusting screw lock nut will be tightened during the steering gear meshload adjustment. Do not tighten the lock nut at this time.
  28. Loosely install the meshload adjusting screw lock nut.
    29. Fig 25: Identifying Meshload Adjusting Screw Lock nut
    GF0007750Courtesy of FORD MOTOR CO.
  29. Rotate the input shaft to the left stop and then back-off approximately 45 degrees.
  30. Using a dial or digital torque wrench and a crow's foot wrench, slowly and evenly rotate the input shaft clockwise 1/2 turn (180 degrees), starting from the 45 degree position. This torque reading is the preload torque.
    • Record the preload torque.
    • The preload torque must be within 0.34-1.36 Nm (3-12 lb-in).
    31. Fig 26: Tightening Input Shaft Clockwise
    GF0007780Courtesy of FORD MOTOR CO.
  31. Rotate the input shaft to its center of travel (approximately 1.5 turns from either stop). Place the torque wrench on the input shaft with the handle in the vertical position. Rotate the torque wrench slowly and evenly 1/4 turn (90 degrees) from each side of center. This torque reading is the on-center torque.
    • Record the torque measured on or near center.
    32. Fig 27: Rotating Input Shaft
    GF0007781Courtesy of FORD MOTOR CO.
    NOTE: The on-center torque must be 0.28-0.79 Nm (2.5-7 lb-in) greater than preload torque without exceeding a total of 2.15 Nm (19 lb-in). The on-center torque minus the preload torque is the meshload torque.
  32. If necessary, carry out the following steps to adjust the on-center torque.
    33. NOTE: Rotate the meshload adjusting screw clockwise to increase the on-center torque and counterclockwise to decrease the on-center torque.
  33. Rotate the meshload adjusting screw until the on-center and meshload torque readings fall within the specified values.
  34. While holding the meshload adjusting screw, tighten the meshload adjusting screw lock nut to 31 Nm (23 lb-ft).
    35. Fig 28: Identifying Meshload Adjusting Screw Lock nut
    GF0007750Courtesy of FORD MOTOR CO.
  35. Install the steering gear. For additional information, refer to Steering Gear .
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