Power Steering Gear: Reassembly

NOTE: Use Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A.

1. Lubricate the sector shaft seal bore of the steering gear housing. See Fig 1. Lubricate the sector shaft seal. Use Sector Shaft Seal Replacer (T77L-3576-A) to install the sector shaft seal. See Fig 2.
   Fig 1: Lubricating Sector Shaft Seal Bore Of Steering Gear Housing

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   Fig 2: Installing Sector Shaft Seal

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2. Install the spacer and the snap ring. See Fig 3 and Fig 4 .
   Fig 3: Installing Spacer

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   Fig 4: Installing Snap Ring

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NOTE: Place the steering gear sector shaft dust seal on sector shaft seal replacer so the raised lip is toward the tool.
3. Lubricate the steering gear sector shaft dust seal. Use sector shaft seal replacer to install the steering gear sector shaft dust seal. See Fig 2.
4. Remove steering gear housing from Bench Mounted Holding Fixture (T57L-500-B). Position the input shaft bearing in the valve housing and use Input Shaft Bearing Seal (T65P-3524-A) and a press to seat the bearing. See Fig 5. Use Input shaft bearing seal set and a press to seat the input shaft seal. See Fig 6.
   Fig 5: Installing Input Shaft Bearing In Valve Housing

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   Fig 6: Seat The Input Shaft Seal

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5. Install the input shaft snap ring. See Fig 7. Use input shaft bearing seal to install the input shaft dust shield. See Fig 8. Mount the valve housing in bench mounted holding fixture. See Fig 9.
   Fig 7: Installing Input Shaft Snap Ring

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   Fig 8: Installing Input Shaft Dust Shield

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   Fig 9: Positioning Valve Housing In Bench Mounted Holding Fixture

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6. Install the power steering gear input shaft and control into the valve housing. See Fig 10.
   Fig 10: Installing Power Steering Gear Input Shaft & Control Into Valve Housing

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7. Position the power steering gear race nut into the valve housing. See Fig 11. Use Adjuster and Locknut Wrench to tighten the power steering gear race nut. See Fig 12.
   Fig 11: Positioning Power Steering Gear Race Nut Into Valve Housing

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   Fig 12: Tightening Power Steering Gear Race Nut

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8. Install the steering gear Allen head race lock nut. See Fig 13. Remove the valve housing from bench mounted holding fixture and position the piston on the worm gear. See Fig 14.
   Fig 13: Install Steering Gear Allen Head Race Lock Nut

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   Fig 14: Position Piston On Worm Gear

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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.
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 properly 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 2-3/4 inches (69.1 mm) 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 may result.
Fig 15: Installing Steering Gear Ball Return Guide On Piston
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Fig 16: Installing 28 Ball Bearings Into Opening In Ball Guide
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9. Install the steering gear ball return guide on the piston. See Fig 15. Rotate the piston while holding the steering gear ball return guide and install the 28 ball bearings into the opening in the ball guide. See Fig 16.
10. Position the ball guide clamp. Install the ball guide clamp bolts. See Fig 17. Install a new gasket and then lubricate and install the Teflon® seal on the valve housing. See Fig 18.
    Fig 17: Installing Ball Guide Clamp

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    Fig 18: Installing New Gasket & Seal On Valve Housing

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11. Make sure to align the oil passages in the gear housing. Install the piston assembly into the gear housing. See Fig 19. Rotate the teeth so they are on the same plane as the sector shaft. See Fig 20.
    Fig 19: Installing Piston Assembly Into Gear Housing

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    Fig 20: Rotating Teeth So They Are On Same Plane As Sector Shaft

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12. If equipped, install the identification tag prior to installing the valve housing bolts. See Fig 21. Loosely install the valve housing bolts. Lubricate the O-ring on the sector shaft housing cover. See Fig 22.
    Fig 21: Installing Valve Housing Bolts

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    Fig 22: Identifying Sector Shaft Housing Cover O-Ring

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NOTE: The sector shaft locknut will be final tightened during the steering gear meshload adjustment.
Fig 23: Installing Sector Shaft Into Housing
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13. Rotate the housing clockwise and install the sector shaft into sector shaft housing. See Fig 23. Install the sector shaft locknut.
14. Loosely install the sector shaft housing bolts. Install the sector shaft housing assembly. See Fig 24.
    Fig 24: Installing Sector Shaft Housing Assembly

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15. Tighten the sector shaft housing cover bolts to specification. See Fig 25. Tighten the valve housing bolts to specification. See Fig 26. Install the steering gear. See POWER STEERING GEAR .
16. Adjust meshload. See MESHLOAD ADJUSTMENT .

Fig 25: Tightening Sector Shaft Housing Cover Bolts

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Fig 26: Tightening Valve Housing Bolt

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