Steering Gear: Assembly

WARNING: This page is about a different car, the 2004 Ford RV Cutaway, 2004 Ford Econoline, 2004 Ford E450 Super Duty, and 2004 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

Lubricate the sector shaft seal bore.
- Use multi-purpose grease.
Fig 1: Lubricating Sector Shaft Seal Bore
Courtesy of FORD MOTOR CO.
Using the special tool, install the sector shaft seal.
- Lubricate the sector shaft seal, using multi-purpose grease.
Fig 2: Installing Sector Shaft Seal
Courtesy of FORD MOTOR CO.
Install the spacer.

Fig 3: Installing Spacer
Courtesy of FORD MOTOR CO.
Install the snap ring.

Fig 4: Installing Snap Ring
Courtesy of FORD MOTOR CO.

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

Courtesy of FORD MOTOR CO.

Using the special tool, install the sector shaft dust seal.
- Lubricate the steering gear sector shaft dust seal using multi-purpose grease.
Remove the steering gear housing from the holding fixture.
Position the input shaft bearing in the valve housing and use the special tool and a press to seat the bearing.

Fig 6: Installing Input Shaft Bearing
Courtesy of FORD MOTOR CO.
Use the special tool and a press to seat the power steering gear input shaft seal.

Fig 7: Installing Power Steering Gear Input Shaft Seal
Courtesy of FORD MOTOR CO.
Install the input shaft snap ring.

Fig 8: Installing Input Shaft Snap Ring
Courtesy of FORD MOTOR CO.
Using the special tool, install the power steering gear input shaft seal dust seal.

Fig 9: Installing Power Steering Gear Input Shaft Seal Dust Seal
Courtesy of FORD MOTOR CO.
Mount the valve housing to the special tool.

Fig 10: Mounting Valve Housing To Special Tool
Courtesy of FORD MOTOR CO.
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
Courtesy of FORD MOTOR CO.
Position the power steering gear race nut into the valve housing.

Fig 12: Positioning Power Steering Gear Race Nut Into Valve Housing
Courtesy of FORD MOTOR CO.
Using the special tool, tighten the race nut.

Fig 13: Tightening Race Nut
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Install the setscrew.

Fig 14: Identifying Tightening Torque Of Setscrew
Courtesy of FORD MOTOR CO.
Remove the valve housing from the holding fixture and position the piston on the worm gear.

Fig 15: Removing Valve Housing From Holding Fixture
Courtesy of FORD MOTOR CO.

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 can 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

Courtesy of FORD MOTOR CO.

Install the steering gear ball return guide on the piston.

WARNING: The correct number of balls are required for correct 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 17: Locating Ball Guide Opening

Courtesy of FORD MOTOR CO.

Rotate the piston while holding the steering gear ball return guide and install the 28 ball bearings into the opening in the ball guide.
Install the steering gear ball return guide clamp.
1. Position the steering gear ball return guide clamp.
2. Install the bolts.
Fig 18: Identifying Tightening Torque Of Steering Gear Ball Return Guide Clamp
Courtesy of FORD MOTOR CO.
Install a new gasket.

Fig 19: Installing Gasket
Courtesy of FORD MOTOR CO.
Lubricate and install the seal on the piston.
- Use multi-purpose grease.
Fig 20: Installing Piston Seal
Courtesy of FORD MOTOR CO.

NOTE: Make sure to align the oil passages in the steering gear housing.

Fig 21: Installing Piston Assembly Into Steering Gear Housing

Courtesy of FORD MOTOR CO.

Install the piston assembly into the steering gear housing.
Rotate the teeth so they are on the same plane as the steering gear sector shaft.

Fig 22: View Of Steering Gear Housing
Courtesy of FORD MOTOR CO.
Loosely install the valve housing bolts and the identification tag, if so equipped.

Fig 23: Installing Valve Housing Bolts
Courtesy of FORD MOTOR CO.
Lubricate the O-ring on the sector shaft housing cover.
- Use multi-purpose grease.
Fig 24: Lubricating O-Ring On Sector Shaft Housing Cover
Courtesy of FORD MOTOR CO.
Rotate the housing clockwise and install the sector shaft into the sector shaft housing.

Fig 25: Installing Sector Shaft Into Sector Shaft Housing
Courtesy of FORD MOTOR CO.

NOTE: The sector shaft lock nut will be tightened during the steering gear meshload adjustment.

Fig 26: Installing Sector Shaft Lock Nut

Courtesy of FORD MOTOR CO.

Install the sector shaft lock nut.

NOTE: Loosely install the sector shaft housing bolts.

Fig 27: Installing Sector Shaft And Housing Assembly

Courtesy of FORD MOTOR CO.

Install the sector shaft and housing assembly.
Tighten the bolts.

Fig 28: Identifying Tightening Torque Of Bolts
Courtesy of FORD MOTOR CO.
Tighten the valve housing bolts.

Fig 29: Identifying Tightening Torque Of Valve Housing Bolts
Courtesy of FORD MOTOR CO.