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Gear -Power Steering: Assembly

  1. Lubricate the sector shaft seal bore.
    • Use Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A.
    Fig 1: Lubricating Sector Shaft Seal Bore
    G03442026Courtesy of FORD MOTOR CO.
  2. Use Sector Shaft Seal Replacer to install the sector shaft seal.
    • Lubricate the sector shaft seal, use Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A.
    Fig 2: Installing Sector Shaft Seal
    G03442027Courtesy of FORD MOTOR CO.
  3. Install the spacer.
    Fig 3: Installing Spacer
    G03442028Courtesy of FORD MOTOR CO.
  4. Install the snap ring.
    Fig 4: Installing Snap Ring
    G03442029Courtesy of FORD MOTOR CO.
    5. NOTE: Place the steering gear sector shaft dust seal on Sector Shaft Seal Replacer so the raised lip is toward the tool.
    Fig 5: Installing Sector Shaft Dust Seal
    G03442030Courtesy of FORD MOTOR CO.
  5. Use Sector Shaft Seal Replacer to install the sector shaft dust seal.
    • 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 Bench Mounted Holding Fixture.
  7. Position the input shaft bearing in the valve housing and use Input Shaft Bearing/Seal Tool Set and a press to seat the bearing.
    Fig 6: Installing Input Shaft Bearing In Valve Housing
    G03442031Courtesy of FORD MOTOR CO.
  8. Use Input Shaft Bearing/Seal Tool and a press to seat the power steering gear input shaft seal.
    Fig 7: Installing Power Steering Gear Input Shaft Seal
    G03442032Courtesy of FORD MOTOR CO.
  9. Install the input shaft snap ring.
    Fig 8: Installing Input Shaft Snap Ring
    G03442033Courtesy of FORD MOTOR CO.
  10. Use Input Shaft Bearing/Seal Tool to install the power steering gear input shaft dust seal.
    Fig 9: Installing Power Steering Gear Input Shaft Dust Seal
    G03442034Courtesy of FORD MOTOR CO.
  11. Mount the valve housing in Bench Mounted Holding Fixture.
    Fig 10: Mounting Valve Housing In Bench Mounted Holding Fixture
    G03442035Courtesy of FORD MOTOR CO.
  12. Install the power steering gear input shaft and control into the valve housing.
    Fig 11: Installing Power Steering Gear Input Shaft & Control Into Valve Housing
    G03442036Courtesy of FORD MOTOR CO.
  13. Position the power steering gear race nut into the valve housing.
    Fig 12: Installing Power Steering Gear Race Nut Into Valve Housing
    G03442037Courtesy of FORD MOTOR CO.
  14. Use Adjuster and Locknut Wrench to tighten the race nut.
    Fig 13: Tightening Race Nut
    G03442038Courtesy of FORD MOTOR CO.
  15. Install the setscrew.
    Fig 14: Installing Setscrew
    G03442039Courtesy of FORD MOTOR CO.
  16. Remove the valve housing from Bench Mounted Holding Fixture and position the piston on the worm gear.
    Fig 15: Installing Piston On Worm Gear
    G03442040Courtesy 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 could cause a vehicle accident. If the ball guides become unseated at any time, remove all the balls and repeat the procedure.
    Fig 16: Installing Steering Gear Ball Return Guide On Piston
    G03442041Courtesy of FORD MOTOR CO.
  17. Install the steering gear ball return guide on the piston.
    18. WARNING: The correct number of balls are required for proper gear operation. Count the balls and insert each carefully.
    WARNING: 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 17: Installing Ball Bearings Into Opening In Ball Guide
    G03442042Courtesy of FORD MOTOR CO.
  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.
  19. Install the steering gear ball return guide clamp.
    1. Position the steering gear ball return guide clamp.
    2. Install the bolts.
    Fig 18: Installing Steering Gear Ball Return Guide Clamp & Bolts
    G03442043Courtesy of FORD MOTOR CO.
  20. Install a new gasket.
    Fig 19: Installing New Gasket
    G03442044Courtesy of FORD MOTOR CO.
  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.
    Fig 20: Installing Seal On Piston
    G03442045Courtesy of FORD MOTOR CO.
    22. NOTE: Make sure to align the oil passages in the steering gear housing.
    Fig 21: Installing Piston Assembly Into Steering Gear Housing
    G03442046Courtesy of FORD MOTOR CO.
  22. Install the piston assembly into the steering gear housing.
  23. Rotate the teeth so they are on the same plane as the steering gear sector shaft.
    Fig 22: Identifying Teeth
    G03442047Courtesy of FORD MOTOR CO.
  24. Loosely install the valve housing bolts and the identification tag, if so equipped.
    Fig 23: Installing Valve Housing Bolts
    G03442048Courtesy of FORD MOTOR CO.
  25. Lubricate the O-ring on the sector shaft housing cover.
    • Use Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A.
    Fig 24: Installing O-Ring On Sector Shaft Housing Cover
    G03442049Courtesy of FORD MOTOR CO.
  26. Rotate the housing clockwise and install the sector shaft into the sector shaft housing.
    Fig 25: Rotating Housing Clockwise
    G03442050Courtesy of FORD MOTOR CO.
    27. NOTE: The sector shaft lock nut will be tightened during the steering gear meshload adjustment.
    Fig 26: Installing Sector Shaft Lock Nut
    G03442051Courtesy of FORD MOTOR CO.
  27. Install the sector shaft lock nut.
    28. NOTE: Loosely install the sector shaft housing bolts.
    Fig 27: Installing Sector Shaft & Housing Assembly
    G03442052Courtesy of FORD MOTOR CO.
  28. Install the sector shaft and housing assembly.
  29. Tighten the bolts.
    Fig 28: Tightening Steering Gear Sector Shaft Housing Cover Bolts
    G03442053Courtesy of FORD MOTOR CO.
  30. Tighten the bolts.
    Fig 29: Tightening Valve Housing Bolts
    G03442054Courtesy of FORD MOTOR CO.
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