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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: Lubricating Sector Shaft Seal Bore
    G02212304Courtesy of FORD MOTOR CO.
  2. Use the Sector Shaft Seal Replacer to 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
    G02212305Courtesy of FORD MOTOR CO.
  3. Install the spacer.
    Fig 3: Installing Spacer
    G02212306Courtesy of FORD MOTOR CO.
  4. Install the snap ring.
    Fig 4: Installing Snap Ring
    G02212307Courtesy of FORD MOTOR CO.
    5. NOTE: Place the steering gear sector shaft dust seal on the Sector Shaft Seal Replacer so the raised lip is toward the tool.
    Fig 5: Installing Sector Shaft Dust Seal
    G02212308Courtesy of FORD MOTOR CO.
  5. Use the Sector Shaft Seal Replacer to 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.
  6. Remove the steering gear housing from the Bench Mounted Holding Fixture.
  7. Position the input shaft bearing in the valve housing and use the Input Shaft Bearing/Seal Tool Set and a press to seat the bearing.
    Fig 6: Pressing To Seat Bearing
    G02212309Courtesy of FORD MOTOR CO.
  8. Use the Input Shaft Bearing/Seal Tool and a press to seat the power steering gear input shaft seal.
    Fig 7: Pressing To Seat Power Steering Gear Input Shaft Seal
    G02212310Courtesy of FORD MOTOR CO.
  9. Install the input shaft snap ring.
    Fig 8: Installing Input Shaft Snap Ring
    G02212311Courtesy of FORD MOTOR CO.
  10. Use the Input Shaft Bearing/Seal Tool to install the power steering gear input shaft dust seal.
    • The dished or rubber side must face away from the valve housing.
    Fig 9: Installing Power Steering Gear Input Shaft Dust Seal
    G02212312Courtesy of FORD MOTOR CO.
  11. Mount the valve housing in the Bench Mounted Holding Fixture.
    Fig 10: Mounting Valve Housing In Bench Mounted Holding Fixture
    G02212313Courtesy of FORD MOTOR CO.
  12. Install the power steering gear input shaft and control into the valve housing.
    Fig 11: Installing Power Steering Gear Input Shaft And Control Into Valve Housing
    G02212314Courtesy of FORD MOTOR CO.
  13. Position the power steering gear race nut into the valve housing.
    Fig 12: Positioning Power Steering Gear Race Nut Into Valve Housing
    G02212315Courtesy of FORD MOTOR CO.
  14. Use the Adjuster and Lock Nut Wrench to tighten the race nut.
    Fig 13: Tightening Race Nut
    G02212316Courtesy of FORD MOTOR CO.
  15. Install the setscrew.
    Fig 14: Installing Setscrew
    G02212317Courtesy of FORD MOTOR CO.
  16. Remove the valve housing from the Bench Mounted Holding Fixture and position the piston on the worm gear.
    Fig 15: Removing Valve Housing
    G02212318Courtesy of FORD MOTOR CO.
    17. 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 16: Installing Steering Gear Ball Return Guide On Piston
    G02212319Courtesy of FORD MOTOR CO.
  17. Install the steering gear ball return guide on the piston.
    18. 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 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 17: Rotating Piston While Holding Steering Gear Ball Return Guide
    G02212320Courtesy of FORD MOTOR CO.
  18. Rotate the piston while holding the steering gear ball return guide and install the 28 ball bearings into the opening in the ball guide.
  19. Install the steering gear ball return guide clamp.
    1. Position the steering gear ball return guide clamp.
    2. Install the bolts.
    Fig 18: Installing Bolts
    G02212321Courtesy of FORD MOTOR CO.
  20. Install a new gasket.
    Fig 19: Installing A New Gasket
    G02212322Courtesy of FORD MOTOR CO.
  21. 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 20: Lubricating And Installing Seal On Piston
    G02212323Courtesy of FORD MOTOR CO.
    22. NOTE: Make sure to align the oil passages in the steering gear housing.
    Fig 21: Installing Piston Assembly Into Steering Gear Housing
    G02212324Courtesy of FORD MOTOR CO.
  22. Install the piston assembly into the steering gear housing.
  23. Rotate the teeth so they are on the same plane as the steering gear sector shaft.
    Fig 22: Rotating Teeth
    G02212325Courtesy of FORD MOTOR CO.
  24. Loosely install the valve housing bolts and the identification tag, if so equipped.
    Fig 23: Installing Valve Housing Bolts
    G02212326Courtesy of FORD MOTOR CO.
  25. 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 24: Lubricating O-Ring On Sector Shaft Housing Cover
    G02212327Courtesy of FORD MOTOR CO.
  26. Rotate the housing clockwise and install the sector shaft into the sector shaft housing.
    Fig 25: Rotating Housing Clockwise
    G02212328Courtesy of FORD MOTOR CO.
    27. NOTE: The sector shaft lock nut will be tightened during the steering gear meshload adjustment.
    Fig 26: Installing Sector Shaft Lock Nut
    G02212329Courtesy of FORD MOTOR CO.
  27. Install the sector shaft lock nut.
    28. NOTE: Loosely install the sector shaft housing bolts.
    Fig 27: Installing Sector Shaft And Housing Assembly
    G02212330Courtesy of FORD MOTOR CO.
  28. Install the sector shaft and housing assembly.
  29. Tighten the bolts.
    Fig 28: Tightening Bolts
    G02212331Courtesy of FORD MOTOR CO.
  30. Tighten the bolts.
    Fig 29: Identifying Tighten Bolts
    G02212332Courtesy of FORD MOTOR CO.
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