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Steering Gear: Disassembly

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: The steering gear input shaft and seals cannot be repaired or installed separately. New gear installation may be necessary.
  1. Secure the steering gear in a vise with the indexing flat pointed down. Use protective caps on the vise jaws.
    Fig 1: Securing Steering Gear
    G03884806Courtesy of FORD MOTOR CO.
  2. Rotate the power steering gear input shaft and control from stop-to-stop and then center the gear.
    Fig 2: Rotating Power Steering Gear Input Shaft
    G03884807Courtesy of FORD MOTOR CO.
  3. Remove the steering gear sector shaft housing cover bolts.
    Fig 3: Removing Steering Gear Sector Shaft Housing Cover Bolts
    G03884808Courtesy of FORD MOTOR CO.
  4. Tap on the lower end of the steering gear sector shaft.
    Fig 4: Identifying Steering Gear Sector Shaft
    G03884809Courtesy of FORD MOTOR CO.
    CAUTION: If there is evidence of damage or wear to the steering gear sector shaft, you must install a new steering gear assembly.
  5. Remove the steering gear sector shaft.
    Fig 5: Removing Steering Gear Sector Shaft
    G03884810Courtesy of FORD MOTOR CO.
  6. Remove the locking nut from the steering gear sector shaft adjustment screw.
    Fig 6: Removing Locking Nut From Steering Gear Sector Shaft Adjustment Screw
    G03884811Courtesy of FORD MOTOR CO.
  7. Remove the sector shaft housing cover.
    • Hold the steering gear sector shaft.
    • Turn the housing cover counterclockwise.
      Fig 7: Removing Sector Shaft Housing Cover
      G03884812Courtesy of FORD MOTOR CO.
  8. Remove the valve housing bolts and the identification tag.
    Fig 8: Removing Valve Housing Bolts And Identification Tag
    G03884813Courtesy of FORD MOTOR CO.
  9. Remove the valve housing and piston assembly.
    Fig 9: Removing Valve Housing And Piston Assembly
    G03884814Courtesy of FORD MOTOR CO.
  10. Remove and discard the gasket.
    Fig 10: Discarding Gasket
    G03884815Courtesy of FORD MOTOR CO.
  11. Remove the ball bearings.
    1. Remove the bolts.
    2. Remove the steering gear ball return guide clamp.
    3. Remove the steering gear ball return guide.
    4. Rotate the piston over a container to collect the 28 steering gear worm balls.
      Fig 11: Removing Steering Gear Ball Return Guide Clamp
      G03884816Courtesy of FORD MOTOR CO.
  12. Remove the input shaft valve and housing assembly from the piston.
    Fig 12: Removing Input Shaft Valve And Housing Assembly From Piston
    G03884817Courtesy of FORD MOTOR CO.
  13. Remove and discard the seal.
    Fig 13: Discarding Seal
    G03905017Courtesy of FORD MOTOR CO.
  14. Place the valve housing in the holding fixture special tool and loosen the setscrew.
    Fig 14: Loosening Setscrew
    G03884819Courtesy of FORD MOTOR CO.
  15. Using the special tool, remove the race nut.
    Fig 15: Removing Race Nut
    G03884820Courtesy of FORD MOTOR CO.
  16. Remove the power steering gear input shaft and control from the valve housing.
    Fig 16: Removing Power Steering Gear Input Shaft And Control From Valve Housing
    G03884821Courtesy of FORD MOTOR CO.
  17. Rotate the valve housing with the holding fixture.
  18. Use the puller to remove the power steering gear input shaft seal dust seal.
    Fig 17: Removing Power Steering Gear Input Shaft Seal Dust Seal
    G03884822Courtesy of FORD MOTOR CO.
  19. Remove the input shaft snap ring.
    Fig 18: Removing Input Shaft Snap Ring
    G03884823Courtesy of FORD MOTOR CO.
  20. Rotate the valve housing with the holding fixture, and using the special tool, remove the bearing and power steering gear input shaft seal.
    Fig 19: Removing Bearing And Power Steering Gear Input Shaft Seal
    G03884824Courtesy of FORD MOTOR CO.
  21. Remove the valve housing from the holding fixture.
  22. Install the steering gear housing in the holding fixture and remove the steering gear sector shaft dust seal from the sector shaft seal bore.
    Fig 20: Removing Steering Gear Sector Shaft Dust Seal From Sector Shaft Seal Bore
    G03884825Courtesy of FORD MOTOR CO.
  23. Remove the spacer.
    1. Remove the snap ring.
    2. Remove the spacer.
      Fig 21: Removing Snap Ring And Spacer
      G03884826Courtesy of FORD MOTOR CO.
    24. NOTE: The steering gear sector shaft bearing is not replaceable.
    Fig 22: Removing Sector Shaft Seal
    G03884827Courtesy of FORD MOTOR CO.
  24. Using the special tool, remove the sector shaft seal.
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