DISASSEMBLY AND ASSEMBLY

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Marilyn Holt
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1 Power Steering DISASSEMBLY AND ASSEMBLY Steering Gear Special Tool(s) Holding Fixture, Transmission (T57L-500-B) Special Tool(s) Installer, Worm Bearing Locknut (T66P-3553-B) Installer, Sector Shaft Seal (T77L-3576-A) Service Set, Steering Gear Bearing and Oil Seal 211-S005 (T65P-3524-A) (Continued) Material Item Multi-Purpose Grease XG-4 and/or XL-5 Threadlock and Sealer TA-25 Specification ESB-M1C93-B WSK-M2G351-A5 Copyright 2003, Ford Motor Company Last updated: 4/20/2007

2 Power Steering Item Part Number Description CAUTION: While repairing the power 1 Meshload adjusting screw steering system, care should be taken to prevent locknut (part of 3L548 seal the entry of contaminants, or failure of the kit) power steering components may result. 2 N Sector shaft housing cover bolt (4 required) NOTE: The steering gear piston assembly cannot Sector shaft housing cover be repaired or installed separately. 4 Sector shaft housing cover seal (part of 3L548 seal kit) 5 Sector shaft and meshload adjusting screw assembly (part of 3504) 6 Steering gear housing (part of 3504) 7 Sector shaft seal (part of 3L548 seal kit) 8 Spacer (part of 3L548 seal kit) 1. Remove the steering gear. For additional information, refer to Steering Gear in this section. Disassembly 1. CAUTION: Use a soft-jawed vise to secure the steering gear or damage to the steering gear housing may occur. Secure the steering gear in a soft-jawed vise. 9 Snap ring (part of 3L548 seal Use protective caps on the vise jaws. kit) 10 Sector shaft dust seal (part of 3L548 seal kit) 11 Valve housing-to-gear housing O-ring seal (part of 3L548 seal kit) 12 Worm thrust bearing retainer ring (part of 3504) 13 Piston assembly (part of 3504) 14 Valve housing seal (part of 3L548 seal kit) Worm thrust bearing retainer ring setscrew (part of 3L548 seal kit) 2. Rotate the steering gear input shaft from Valve housing (part of 3504) stop-to-stop and record the number of rotations Valve housing bolt (4 required) Rotate the input shaft in the opposite direction 1/2 of the total rotations recorded 18 Input shaft bearing (part of 3504) to center the gear. 19 Input shaft seal (part of 3L548 seal kit) 20 Snap ring (part of 3L548 seal kit) 21 Input shaft dust seal (part of 3L548 seal kit)

3 Power Steering Remove and discard the meshload adjusting screw locknut. 4. Remove the 4 steering gear sector shaft housing cover bolts. 6. Remove and discard the sector shaft housing cover seal. 7. CAUTION: If there is evidence of damage, scratches or wear to the sector shaft, a new steering gear assembly must be 5. CAUTION: If there is evidence of installed or a fluid leak may occur. damage, scratches or wear to the steering Using a soft mallet, gently tap on the lower end gear/sector shaft housing sealing area, a new of the sector shaft and remove the sector shaft. steering gear must be installed or a fluid leak may occur. Inspect the sector shaft. Rotate the meshload adjusting screw clockwise until the sector shaft housing cover is separated from the adjuster screw. Inspect the sector shaft housing cover bore.

4 Power Steering Remove the 4 valve housing bolts. 9. Remove the valve housing and piston assembly. 12. Using the special tool, remove the worm thrust bearing retainer ring. 13. Remove the input shaft and control from the 10. Remove and discard the valve housing seal. valve housing. 11. Place the valve housing in the special tool and 14. Rotate the holding fixture 180 degrees. remove the worm thrust bearing retainer ring setscrew. Discard the setscrew.

5 Power Steering CAUTION: Do not allow the screwdriver to make contact with the valve housing bore, or damage to the sealing area may occur, causing a fluid leak. Using a screwdriver, remove and discard the input shaft dust seal. 19. Remove the valve housing from the holding fixture. 20. Reposition the steering gear in the vise to access the sector shaft seals. 16. Remove and discard the input shaft seal snap ring. 21. CAUTION: Do not allow the screwdriver to make contact with the sector shaft seal bore, or damage to the sealing area may occur, causing a fluid leak. Using a screwdriver, remove and discard the sector shaft dust seal. 17. Rotate the holding fixture 180 degrees. 18. Using the special tool, remove the input shaft bearing and input shaft seal. Discard the input shaft seal.

6 Power Steering Remove the sector shaft seal snap ring and spacer. Discard the snap ring. Assembly 23. CAUTION: Do not allow the seal puller to make contact with the sector shaft seal bore, or damage to the sealing area may occur, causing a fluid leak. NOTE: The steering gear sector shaft bearing is not serviceable. Using a suitable seal puller, remove and discard the sector shaft seal. Inspect the sector shaft seal bore. 1. Lubricate the sector shaft seal bore with multi-purpose grease. 2. NOTE: Lubricate the sector shaft seal and spacer with multi-purpose grease. 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. 24. Remove and discard the valve housing-to-gear housing O-ring seal.

7 Power Steering Install the new sector shaft seal snap ring. 6. Using the press and the special tool, install the new input shaft seal. 4. NOTE: Place the sector shaft dust seal on the special tool so the raised lip is toward the tool. 7. Install the new input shaft housing snap ring. Using the special tool, install the new sector Lubricate the top of the input shaft seal with shaft dust seal. multi-pupose grease. Lubricate the steering gear sector shaft dust seal with multi-purpose grease. 8. NOTE: Place the input shaft dust seal on the special tool so the raised lip is toward the tool. 5. Position the input shaft bearing in the valve Using the special tool, install the new input housing. shaft dust seal. Using a suitable press and the special tool, seat the bearing.

8 Power Steering Mount the valve housing to the special tool. 10. Install the input shaft and control into the valve housing. 13. Install the new worm thrust bearing retainer ring setscrew. Tighten to 2 Nm (18 lb-in). 11. Position the steering gear worm thrust bearing retainer ring into the valve housing. 14. Secure the steering gear housing in the soft-jawed vice. 15. Install the new valve housing-to-gear housing O-ring seal. 12. Using the special tool, tighten the worm thrust bearing retainer ring. Tighten to 99 Nm (73 lb-ft).

9 Power Steering Install the new valve housing seal. 17. Lubricate the piston seal with multi-purpose grease. 20. Install the sector shaft into the steering gear housing. 18. Install the piston assembly into the steering gear housing. 21. Apply threadlock and install the 4 valve housing bolts. Tighten to 51 Nm (38 lb-ft). 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.

10 Power Steering Install a new O-ring on the sector shaft housing cover and lubricate with multi-purpose grease. 26. CAUTION: Do not exceed 31 Nm (23 lb-ft) when applying pressure to the sector shaft housing, or damage to the housing may 23. Place the sector shaft housing cover on the occur. meshload adjusting screw and rotate the adjusting screw counterclockwise until the Install an original steering gear mounting bolt sector shaft housing cover is drawn into the into the steering gear housing, applying pressure steering gear housing and the adjusting screw to the side of the sector shaft housing. bottoms out. Tighten the steering gear mounting bolt to 25 Nm (18 lb-ft). 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. 27. Tighten the 4 sector shaft housing cover bolts to 68 Nm (50 lb-ft). Remove the steering gear mounting bolt.

11 Power Steering CAUTION: A new meshload adjusting screw locknut must be installed or a fluid leak at the meshload adjusting screw may occur. NOTE: The meshload adjusting screw locknut will be tightened during the steering gear meshload adjustment. Do not tighten the locknut at this time. Loosely install the meshload adjusting screw locknut. 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. 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. 32. NOTE: The on-center torque must be 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. 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 Record the preload torque. counterclockwise to decrease the on-center The preload torque must be within torque. Nm (3-12 lb-in). Rotate the meshload adjusting screw until the on-center and meshload torque readings fall within the specified values.

12 Power Steering While holding the meshload adjusting screw, 35. Install the steering gear. For additional tighten the meshload adjusting screw locknut to information, refer to Steering Gear in this 31 Nm (23 lb-ft). section.

DISASSEMBLY AND ASSEMBLY

205-02B-1 DISASSEMBLY AND ASSEMBLY Differential Case and Ring Gear Material Item Specification 205-02B-1 Special Tool(s) Additive Friction Modifier EST-M2C118-A XL-3 2-Jaw Puller 205-D072 (D97L-4221-A)