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Gear -Power Steering: Disassembly

NOTE: The steering gear input shaft and seals cannot be repaired or replaced separately. Gear replacement may be necessary.
  1. Secure the steering gear in a vise with the indexing flat pointed down. Use protective caps on the vise jaws.
    Fig 1: Securing Steering Gear In Vise
    G03442004Courtesy of FORD MOTOR CO.
  2. Rotate the power steering gear input shaft and control (3D517) from stop to stop and then center the gear.
    Fig 2: Rotating Power Steering Gear Input Shaft & Control
    G03442005Courtesy of FORD MOTOR CO.
  3. Remove the steering gear sector shaft housing cover bolts.
    Fig 3: Removing Steering Gear Sector Shaft Housing Cover Bolts
    G03442006Courtesy of FORD MOTOR CO.
  4. Tap on the lower end of the steering gear sector shaft (3575).
    Fig 4: Tapping On Lower End Of Steering Gear Sector Shaft
    G03442007Courtesy of FORD MOTOR CO.
  5. Remove the steering gear sector shaft.
    Fig 5: Removing Steering Gear Sector Shaft
    G03442008Courtesy of FORD MOTOR CO.
  6. Remove the locking nut from the steering gear sector shaft adjustment screw.
    Fig 6: Removing Locking Nut From Steering Gear Sector Shaft Adjustment Screw
    G03442009Courtesy of FORD MOTOR CO.
  7. Remove the sector shaft housing cover.
    • Hold the steering gear sector shaft.
    • Turn the housing cover counterclockwise.
    Fig 7: Removing Sector Shaft Housing Cover
    G03442010Courtesy of FORD MOTOR CO.
  8. Remove the valve housing bolts and the identification tag.
    Fig 8: Removing Valve Housing Bolts
    G03442011Courtesy of FORD MOTOR CO.
  9. Remove the valve housing and piston assembly.
    Fig 9: Removing Valve Housing & Piston Assembly
    G03442012Courtesy of FORD MOTOR CO.
  10. Remove and discard the gasket.
    Fig 10: Removing Gasket
    G03442013Courtesy of FORD MOTOR CO.
  11. Remove the ball bearings.
    1. Remove the bolts.
    2. Remove the steering gear ball return guide clamp (3544).
    3. Remove the steering gear ball return guide (3523).
    4. Rotate the piston over a container to collect the 28 steering gear worm balls (3647).
    Fig 11: Removing Ball Bearings & Components
    G03442014Courtesy of FORD MOTOR CO.
  12. Remove the input shaft valve and housing assembly from the piston.
    Fig 12: Removing Input Shaft Valve & Housing Assembly From Piston
    G03442015Courtesy of FORD MOTOR CO.
  13. Remove and discard the seal.
    Fig 13: Removing Seal
    G03442016Courtesy of FORD MOTOR CO.
  14. Install the valve housing in Bench Mounted Holding Fixture and loosen the setscrew.
    Fig 14: Installing Valve Housing In Bench Mounted Holding Fixture & Loosening Setscrew
    G03442017Courtesy of FORD MOTOR CO.
  15. Use Adjuster and Locknut Wrench to remove the race nut.
    Fig 15: Removing Race Nut
    G03442018Courtesy of FORD MOTOR CO.
  16. Remove the power steering gear input shaft and control from the valve housing.
    Fig 16: Removing Power Steering Gear Input Shaft & Control From Valve Housing
    G03442019Courtesy of FORD MOTOR CO.
  17. Rotate the valve housing with Bench Mounted Holding Fixture.
  18. Use Puller to remove the power steering gear input shaft seal (3D526) dust seal.
    Fig 17: Removing Power Steering Gear Input Shaft Dust Seal
    G03442020Courtesy of FORD MOTOR CO.
  19. Remove the input shaft snap ring.
    Fig 18: Removing Input Shaft Snap Ring
    G03442021Courtesy of FORD MOTOR CO.
  20. Rotate the valve housing with Bench Mounted Holding Fixture and use Input Shaft Bearing/Seal Tool to remove the bearing and power steering gear input shaft seal.
    Fig 19: Removing Bearing & Power Steering Gear Input Shaft Seal
    G03442022Courtesy of FORD MOTOR CO.
  21. Remove the valve housing from Bench Mounted Holding Fixture.
  22. Install the steering gear housing (3548) in Bench Mounted Holding Fixture and remove the steering gear sector shaft dust seal from the sector shaft seal bore.
    Fig 20: Removing Steering Gear Sector Shaft Dust Seal From Sector Shaft Seal Bore
    G03442023Courtesy of FORD MOTOR CO.
  23. Remove the spacer.
    1. Remove the snap ring.
    2. Remove the spacer.
    Fig 21: Removing Snap Ring & Spacer
    G03442024Courtesy of FORD MOTOR CO.
    24. NOTE: The steering gear sector shaft bearing is not replaceable.
    Fig 22: Removing Sector Shaft Seal
    G03442025Courtesy of FORD MOTOR CO.
  24. Use Puller to remove the sector shaft seal.
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