Pinion Shaft & Spool Valve Assembly: Reassembly

1. Using Lower Pinion Bearing Replacer, install steering gear lower pinion bearing in gear housing. Support valve housing with a wood block and seat bearing against shoulder in bore.
2. Apply Steering Gear Grease (C3AZ-19578-A) to pinion oil seal. Place pinion oil seal in Lower Pinion Seal Replacer with seal lip facing seal replacer. Support pinion housing on a flat surface and install seal in valve bore. Ensure seal is seated against shoulder.
3. Mount pinion end of valve assembly in soft-jawed vise. Lubricate Mandrel (T75L-3517-A1) with power steering fluid. Install mandrel over valve assembly and slide one valve sleeve ring over mandrel. Slide Pusher (T75L-3517-A2) over mandrel. See Fig 1 .
4. Push down on pusher, forcing ring down ramp and into fourth groove of valve sleeve. Repeat procedure for each spacer. After 4 valve sleeve rings are installed, apply a light coat of Steering Gear Grease (C3AZ-19578-A) to sleeve and rings.
   Fig 1: Assembling Seal On Valve

   Courtesy of FORD MOTOR CO.
5. Install Spacer (T75L-3517-A3) over pinion shaft as a pilot for installation of Teflon Sizing Tube over sleeve valve end of pinion shaft onto valve sleeve rings.
6. Ensure rings are not bent over as tube is slid over them. Remove sizing tube and check condition of rings. Ensure rings turn freely in grooves.
7. Insert Valve Body Inserter (T78P-3504-C) into valve housing.
8. Turn pinion shaft with Pinion Shaft Torque Adapter. Ensure pinion is centered by counting number of turns from center to each stop.
9. Number of turns should be approximately 1 1/2 turns for variable ratio gear or 1 1/4 turns for constant ratio gear. If turns are unequal, pull valve assembly out far enough to free pinion teeth. Rotate pinion shaft 60 degrees (one tooth) in direction that required fewer turns. Insert valve assembly and ensure it is centered. Repeat procedure as necessary.
10. Install NEW nut on pinion end of valve assembly (if required). Hold pinion shaft with torque adapter. Ensure rack is away from its stops. Tighten nut to specification. See TORQUE SPECIFICATIONS  . Install bearing in valve bore. Seat bearing with Upper Pinion Bearing Seal Replacer (T78P-3504-D).
11. Apply a thin coat of Steering Gear Grease (C3AZ-19578-A) to input shaft seal. Install seal with lip toward valve. Seat seal with bearing/seal replacer. Install snap ring in valve bore. Coat pinion shaft in dust seal contact area with Multi-Purpose Grease (D0AZ-19584-AA). Using Dust Seal Installer (T85T-3504-CH1), drive pinion shaft dust seal into position. See Fig 2 . Install steering gear housing pinion bearing cap and tighten to specification. See TORQUE SPECIFICATIONS  .
12. Check for burrs in yoke housing. Fill yoke housing with approximately 2 ounces of gear lubricant. Install plastic yoke, ensuring it seats against rack with finger pressure.
13. Install yoke thrust spring, yoke plug and yoke plug lock nut. Before tightening lock nut, set rack yoke plug preload. See RACK YOKE PRELOAD  under ADJUSTMENTS.

Fig 2: Installing Dust Seal

Courtesy of FORD MOTOR CO.