Steering Gear: Assembly

Lubricate the sector shaft seal bore.
- Use multi-purpose grease.
  
  Fig 1: Lubricating Sector Shaft Seal Bore
  Courtesy of FORD MOTOR CO.
Using the special tool, install the sector shaft seal.
- Lubricate the sector shaft seal, using multi-purpose grease.
  
  Fig 2: Installing Sector Shaft Seal
  Courtesy of FORD MOTOR CO.
Install the spacer.

Fig 3: Locating Spacer
Courtesy of FORD MOTOR CO.
Install the snap ring.

Fig 4: Locating Snap Ring
Courtesy of FORD MOTOR CO.

NOTE: Place the steering gear sector shaft dust seal on the Sector Shaft Seal Replacer so the raised lip is toward the tool.

Using the special tool, install the sector shaft dust seal.
- Lubricate the steering gear sector shaft dust seal using multi-purpose grease.
  
  Fig 5: Installing Steering Gear Sector Shaft Dust Seal
  Courtesy of FORD MOTOR CO.
Remove the steering gear housing from the holding fixture.
Position the input shaft bearing in the valve housing and use the special tool and a press to seat the bearing.

Fig 6: Pressing Seat Bearing
Courtesy of FORD MOTOR CO.
Using the special tool and a press, seat the power steering gear input shaft seal.

Fig 7: Locating Power Steering Gear Input Shaft Seal
Courtesy of FORD MOTOR CO.
Install the input shaft snap ring.

Fig 8: Locating Input Shaft Snap Ring
Courtesy of FORD MOTOR CO.
Using the special tool, install the power steering gear input shaft seal dust seal.

Fig 9: Installing Power Steering Gear Input Shaft Dust Seal
Courtesy of FORD MOTOR CO.
Mount the valve housing to the special tool.

Fig 10: Valve Housing Mounted To Special Tool
Courtesy of FORD MOTOR CO.
Install the power steering gear input shaft and control into the valve housing.

Fig 11: Installing Power Steering Gear Input Shaft
Courtesy of FORD MOTOR CO.
Position the power steering gear race nut into the valve housing.

Fig 12: Positioning Power Steering Gear Race Nut Into Valve Housing
Courtesy of FORD MOTOR CO.
Using the special tool, tighten the race nut.
- Tighten to 99 Nm (73 lb-ft).
  
  Fig 13: Tightening Race Nut
  Courtesy of FORD MOTOR CO.
Install the setscrew.
- Tighten to 2.3 Nm (20 lb-in).
  
  Fig 14: Locating Setscrew
  Courtesy of FORD MOTOR CO.
Remove the valve housing from the holding fixture and position the piston on the worm gear.

Fig 15: Valve Housing And Holding Fixture
Courtesy of FORD MOTOR CO.

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. Failure to follow these instructions may result in personal injury.

Fig 16: Locating Steering Gear Ball Return Guide On Piston

Courtesy of FORD MOTOR CO.

Install the steering gear ball return guide on the piston.

WARNING: The correct number of balls are required for correct gear operation. Count the balls and insert each carefully. Failure to follow these instructions may result in personal injury.

WARNING: To make sure the balls are correctly 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. Failure to follow these instructions may result in personal injury.

Fig 17: Rotating Piston

Courtesy of FORD MOTOR CO.

Rotate the piston while holding the steering gear ball return guide and install the 28 ball bearings into the opening in the ball guide.
Install the steering gear ball return guide clamp.
1. Position the steering gear ball return guide clamp.
2. Install the bolts.
  - Tighten to 6 Nm (53 lb-in).
    
    Fig 18: Locating Steering Gear Ball Return Guide Clamp
    Courtesy of FORD MOTOR CO.
Install a new gasket.

Fig 19: Installing New Gasket
Courtesy of FORD MOTOR CO.
Lubricate and install the seal on the piston.
- Use multi-purpose grease.
  
  Fig 20: Installing Seal On Piston
  Courtesy of FORD MOTOR CO.

NOTE: Make sure to align the oil passages in the steering gear housing.

Fig 21: Installing Piston Assembly Into Steering Gear Housing

Courtesy of FORD MOTOR CO.

Install the piston assembly into the steering gear housing.
Rotate the teeth so they are on the same plane as the steering gear sector shaft.

Fig 22: Identifying Steering Gear Sector Shaft Teeth
Courtesy of FORD MOTOR CO.
Loosely install the valve housing bolts and the identification tag, if so equipped.

Fig 23: Installing Valve Housing Bolts
Courtesy of FORD MOTOR CO.
Lubricate the O-ring on the sector shaft housing cover.
- Use multi-purpose grease.
  
  Fig 24: Lubricating O-Ring On Sector Shaft Housing Cover
  Courtesy of FORD MOTOR CO.
Rotate the housing clockwise and install the sector shaft into the sector shaft housing.

Fig 25: Rotating Housing Clockwise
Courtesy of FORD MOTOR CO.

NOTE: The sector shaft lock nut will be tightened during the steering gear meshload adjustment.

Fig 26: Installing Sector Shaft Lock Nut

Courtesy of FORD MOTOR CO.

Install the sector shaft lock nut.

NOTE: Loosely install the sector shaft housing bolts.

Fig 27: Installing Sector Shaft & Housing Assembly

Courtesy of FORD MOTOR CO.

Install the sector shaft and housing assembly.
Tighten the bolts.
- Tighten to 68 Nm (50 lb-ft).
  
  Fig 28: Locating Bolts
  Courtesy of FORD MOTOR CO.
Tighten the valve housing bolts.
- Tighten to 50 Nm (37 lb-ft).
  
  Fig 29: Locating Valve Housing Bolts
  Courtesy of FORD MOTOR CO.