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Steering Gear: Reassembly

  1. Install Mandrel (T75L-3517-A1) over rotary valve sleeve. Slide one Teflon ring over mandrel. Slide Pusher (T75L-3517-A2) over mandrel. Rapidly push down on pusher, forcing Teflon ring down ramp and into fourth groove of rotary valve sleeve.
  2. Repeat procedure 3 more times, adding Spacer (T75L-3517-A3) under mandrel each time. After installing 4 Teflon rings, apply gear lubricant to rotary valve sleeve and Teflon rings. Install one spacer over input shaft as a pilot for installing sizing tube.
  3. Slowly install Sizing Tube (T75L-3517-A4) over rotary valve sleeve valve end of worm shaft onto Teflon rings. Ensure rings are NOT bent. Sizing tube must be able to slide over rings. Remove sizing tube and check condition of Teflon rings. Teflon rings must turn freely in grooves.
  4. Coat new tube seats with petroleum jelly. Install new tube seats using Brass Tube Installer (T74P-3504-M). Coat bearing and seal surface of housing with petroleum jelly. Position bearing in control valve housing. Press bearing with metal-covered side facing outward. Ensure bearing rotates freely.
  5. Dip NEW oil seal in gear lube. Place seal in housing, metal side out. Drive seal into housing until outer edge does not quite clear snap ring groove. Place snap ring in housing. Drive snap ring in until seated in groove.
  6. With rubber side out, drive dust seal in position behind groove in input shaft. Lubricate seals and sector shaft bore. Place dust seal on Shaft Seal Installer (T77L-3576-A) so raised lip of seal is toward tool.
  7. Slide pressure seal on tool with flat of pressure seal against flat of dust seal. Carefully insert seals into sector shaft bore with tool until they clear snap ring groove. DO NOT  bottom seals against bearing. Install snap ring.
  8. Dip NEW "O" ring in gear lubricant. Install "O" ring on piston and ball nut. Install a NEW plastic ring on piston and ball nut. DO NOT  stretch plastic ring any more than necessary. Mount valve housing in holding fixture (flanged end up).
  9. Lubricate valve sleeve rings. Install worm and valve in gear housing. Using Adjuster/Lock Nut Wrench (T66P-3553-B) and Spacer Valve Housing-to-Piston Holder (T66P-3553-C), install and tighten race nut to specification. See TORQUE SPECIFICATIONS  . See Figure .
  10. Install Allen head set screw through control valve housing. Tighten set screw to specification. See TORQUE SPECIFICATIONS  . Place piston on bench, with ball bearing guide holes facing up. Insert worm shaft so first groove is aligned with hole nearest center of piston.
  11. Place ball guide in piston. While turning worm shaft clockwise, as viewed from input end of shaft, place at least 27 ball bearings in ball bearing guide. See Fig 1 . If all ball bearings have not been fed into guide upon reaching right stop, rotate input shaft back and forth while installing remaining ball bearings.
    NOTE: After installing all ball bearings, DO NOT  rotate input shaft more than 3 turns from right stop, or ball bearings will fall out.
  12. Secure guides in ball bearing nut with clamp and tighten screws to specification. See TORQUE SPECIFICATIONS  . See Fig 1 . Apply petroleum jelly to seal on piston. Place NEW "O" ring on valve housing. Slide piston and valve into gear housing. Align oil passage in valve housing with passage in gear housing.
    Fig 1: Installing Piston & Worm Shaft Ball Bearings
    G95D12966Courtesy of FORD MOTOR CO.
  13. Position NEW "O" ring in gear housing oil passage. Install, but do not tighten, identification tag and attaching bolts. Rotate ball nut so teeth are parallel with sector teeth. Tighten valve housing bolts to specification. Install sector shaft cover "O" ring in gear housing. Turn input shaft to center piston.
  14. Apply petroleum jelly to sector shaft journal. Position sector shaft and cover assembly in gear housing. Rotate input shaft one turn on either side of center. Install and tighten cover bolts to specification. See TORQUE SPECIFICATIONS  . Adjust sector shaft. See SECTOR SHAFT MESH LOAD  under ADJUSTMENTS.
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