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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: Identifying Sector Shaft Seal Bore
    G01941935Courtesy of FORD MOTOR CO.
  2. Using the special tool, install the sector shaft seal.
    • Lubricate the sector shaft seal, using Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A.
    Fig 2: Installing Sector Shaft Seal
    G01941936Courtesy of FORD MOTOR CO.
  3. Install the spacer.
    Fig 3: Identifying Spacer
    G01941937Courtesy of FORD MOTOR CO.
  4. Install the snap ring.
    Fig 4: Identifying Spacer Snap Ring
    G01941938Courtesy of FORD MOTOR CO.
    5. NOTE: Place the steering gear sector shaft dust seal on the special tool so the raised lip is toward the tool.
  5. Using the special tool, 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.
      Fig 5: Installing Sector Shaft Dust Seal
      G01941939Courtesy of FORD MOTOR CO.
    • Fill the space between the steering sector shaft dust seal and the sector shaft seal with 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 the special tool 307-003 (T57L-500-B).
  7. Position the input shaft bearing in the valve housing. Using the special tool and a press, seat the input shaft bearing.
    Fig 6: Seating Input Shaft Bearing
    G01941940Courtesy of FORD MOTOR CO.
  8. Using the special tool, and a press, seat the power steering gear input shaft seal.
    Fig 7: Seating Power Steering Gear Input Shaft Seal
    G01941941Courtesy of FORD MOTOR CO.
  9. Install the input shaft snap ring.
    Fig 8: Identifying Input Shaft Snap Ring
    G01941942Courtesy of FORD MOTOR CO.
  10. Apply a liberal amount of Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A to the seal lip and the top surface of the power steering gear input shaft seal.
    Fig 9: Identifying Seal Lip & Top Surface Of Power Steering Gear Input Shaft Seal
    G01941943Courtesy of FORD MOTOR CO.
  11. Using the special tool, install the power steering gear input shaft dust seal.
    • The dished or rubber side must face away from the valve housing.
    Fig 10: Identifying Input Shaft Bearing/Seal Tool
    G01941944Courtesy of FORD MOTOR CO.
  12. Mount the valve housing in the special tool.
    Fig 11: Identifying Valve Housing & Bench Mounted Holding Fixture
    G01941945Courtesy of FORD MOTOR CO.
  13. Install the power steering gear input shaft and control into the valve housing.
    Fig 12: Installing Power Steering Gear Input Shaft & Control
    G01941946Courtesy of FORD MOTOR CO.
  14. Position the power steering gear race nut into the valve housing.
    Fig 13: Identifying Power Steering Gear Race Nut
    G01941947Courtesy of FORD MOTOR CO.
  15. Using the special tool, tighten the race nut.
    Fig 14: Tightening Race Nut
    G01941948Courtesy of FORD MOTOR CO.
  16. Install the setscrew.
    Fig 15: Tightening Setscrew
    G01941949Courtesy of FORD MOTOR CO.
  17. Remove the valve housing from the special tool 307-003 (T57L-500-B). Position the piston on the worm gear.
    Fig 16: Positioning Piston On Worm Gear
    G01941950Courtesy of FORD MOTOR CO.
    18. 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 17: Identifying Steering Gear Ball Return Guide
    G01941951Courtesy of FORD MOTOR CO.
  18. Install the steering gear ball return guide on the piston.
    19. 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 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.
    Fig 18: Installing Ball Bearings
    G01941952Courtesy of FORD MOTOR CO.
  19. Rotate the piston while holding the steering gear ball return guide and install the 27-29 ball bearings into the opening in the ball guide.
  20. Install the steering gear ball return guide clamp.
    1. Position the steering gear ball return guide clamp.
    2. Install the bolts.
    Fig 19: Tightening Steering Gear Ball Return Guide Clamp Bolts
    G01941953Courtesy of FORD MOTOR CO.
  21. Install a new seal ring.
    Fig 20: Identifying Seal Ring
    G01941954Courtesy of FORD MOTOR CO.
  22. 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 21: Identifying Piston Seal
    G01941955Courtesy of FORD MOTOR CO.
  23. Install the piston assembly into the steering gear housing. Make sure to align the oil passages in the steering gear housing.
    Fig 22: Installing Piston Assembly Into Steering Gear Housing
    G01941956Courtesy of FORD MOTOR CO.
  24. Rotate the teeth so they are on the same plane as the steering gear sector shaft.
    Fig 23: Identifying Steering Gear Teeth
    G01941957Courtesy of FORD MOTOR CO.
  25. Loosely install the valve housing bolts and the identification tag, if so equipped.
    Fig 24: Identifying Valve Housing Bolts
    G01941958Courtesy of FORD MOTOR CO.
  26. 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 25: Identifying O-Ring
    G01941959Courtesy of FORD MOTOR CO.
  27. Rotate the housing clockwise and install the sector shaft into the sector shaft housing.
    Fig 26: Identifying Sector Shaft Housing
    G01941960Courtesy of FORD MOTOR CO.
  28. Install the sector shaft lock nut. The sector shaft lock nut will be tightened during the steering gear meshload adjustment.
    Fig 27: Identifying Sector Shaft Lock Nut
    G01941961Courtesy of FORD MOTOR CO.
  29. Install the sector shaft and housing assembly. Loosely install the sector shaft housing bolts.
    Fig 28: Installing Sector Shaft & Housing Assembly
    G01941962Courtesy of FORD MOTOR CO.
  30. Tighten the bolts.
    Fig 29: Tightening Sector Shaft & Housing Bolts
    G01941963Courtesy of FORD MOTOR CO.
  31. Tighten the bolts.
    Fig 30: Tightening Valve Housing Bolts
    G01941964Courtesy of FORD MOTOR CO.
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