FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
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Home >> Mercury >> 1982 >> Capri V8-302 5.0L >> Repair and Diagnosis >> Steering and Suspension >> Steering >> Steering Gear >> Service and Repair >> Disassembly/Assembly >> Power

Power

Fig. 1 Disassembled view of TRW power rack & pinion steering gear. Capri, Fairmont, Mustang, Mustang SVO & Zephyr:




Fig. 3 Tie rod ball socket assembly removal & installation. Capri, Fairmont, Mustang & Zephyr:





TIE ROD BALL SOCKETS

Disassemble
1. Position steering gear on holding fixture T57L-500-B, or equivalent.
2. Remove tie rod ends and lock nuts, Fig. 1. Mark position of tie rod end on tie rod for reassembly.
3. Remove bellow clamps, bellows and breather tube. Use care not to damage bellows.
4. Using an easy out, remove spiral pin which locks each tie rod socket to the rack.
5. The following tools must be used to remove the socket, tool No. T74P-3504-U, or equivalent, a torque wrench and a crescent wrench to hold the rack from rotating, Fig. 3. If the rack is not held from rotating, damage to rack or pinion teeth may result.

Fig. 3 Tie rod ball socket assembly removal & installation. Capri, Fairmont, Mustang & Zephyr:





Assemble
1. Install and tighten ball sockets hand tight.
2. Using a crescent wrench to prevent rack from turning, tighten lefthand socket to a torque of 55 to 65 ft. lbs. using tool No. T74P-3504-U, or equivalent, Fig. 3. If rack is not restrained from rotating, damage to rack or pinion teeth may result.
3. Install spiral pin for left hand socket using a pair of pliers and a small hammer.
4. Restrain lefthand tie rod ball socket from turning while tightening right hand ball socket to a torque of 55 to 65 ft. lbs., then install spiral pin.
5. Install bellows, breather tube and clamps. Using tool No. T63P-9171-A, or equivalent, to secure clamps properly.
6. Install tie rod ends and locknuts.

Fig. 2 Yoke plug locknut removal & installation. Capri, Fairmont, Mustang & Zephyr:





VALVE & VALVE HOUSING

Disassemble
1. Position steering gear in holding fixture T57L-500-B, or equivalent.
2. Remove pressure lines from valve and gear housing, also remove four small flare gaskets from ports.
3. Loosen yoke plug lock nut, then loosen yoke plug to relieve preload from rack, Fig. 2.
4. Using a 1{1-8} in. socket, remove pinion bearing plug.
5. Position tool No. T74P-3504-R, or equivalent, on input shaft. While holding pinion shaft, remove pinion bearing locknut using a suitable {11-16} in. socket, TRP4. Discard locknut.
6. Remove three bolts and washers attaching valve housing to gear housing.
7. Move rack to left stop. Mark position of flat on input shaft splines to valve housing face for reassembly.
8. Remove pinion bearing locknut, then carefully work valve housing and valve assembly as unit out of gear housing.
9. Position valve and housing assembly in holding fixture, then grip the protruding pinion seal with suitable pliers and rotate the seal clockwise to remove. Do not hammer or pry on the pliers or input shaft.

Fig. 5 Pinion bearing removal. Capri, Fairmont, Mustang & Zephyr:




Fig. 6 Input shaft support bearing removal. Capri, Fairmont, Mustang & Zephyr:





10. Remove pinion bearing from gear housing using tool Nos. T50T-100-A and T58L-101-A, or equivalents, Fig. 5.
11. Using tool No. T71P-19703-C, or equivalent, remove four O-rings from input shaft and valve assembly, if necessary. Use care not to damage land or grooves on valve.
12. Using tool Nos. T50T-100-A and T58L-101-A, or equivalent remove input shaft support bearing from valve housing bore, Fig. 6. Remove oil seal from housing bore.
13. Using a suitable tool, pry input shaft dust seal out of valve housing. Use care not to damage surfaces of valve housing.

Fig. 7 Input shaft dust seal installation. Capri, Fairmont, Mustang & Zephyr:




Fig. 8 Input shaft support bearing installation. Capri, Fairmont, Mustang & Zephyr:




Fig. 9 Installing plastic O-rings on valve assembly. Capri, Fairmont, Mustang & Zephyr:




Fig. 10 Installing valve assembly into valve housing. Capri, Fairmont, Mustang & Zephyr:




Fig. 11 Lower pinion bearing installation. Capri, Fairmont, Mustang & Zephyr:





Assemble
1. Install input shaft oil seal in valve housing. Seal lip must face inside of housing. Ensure seal is bottomed in housing to avoid contact with input shaft bearing.
2. Fill input shaft dust seal bore with lubricant DOAZ-19584-A or equivalent, then install dust seal using tool No. T74P-3504-N, or equivalent, Fig. 7.
3. Lubricate input shaft bearing with power steering fluid, then install bearing in housing using tool No. T74P-3504-P, or equivalent, Fig. 8. The tool will position the bearing at the proper depth to avoid contact with oil seal.
4. Install four O-rings in grooves on valve housing, using tool Nos. T74P-3504-G and T71P-19703-C, or equivalent, Fig. 9.
5. Lubricate thrust washer with power steering fluid, then install thrust washer over input shaft.
6. Lubricate O-rings and valve assembly with power steering fluid. Insert valve assembly splined end first, into large opening of tool No. T74P-3504-H, or equivalent, Fig. 10. Position tool and valve assembly over valve housing bore. Push tool and valve assembly into housing until valve is bottomed and pinion shaft splines pass through dust seal.
7. Carefully position pinion seal on pinion shaft, then slide seal on shaft until it contacts valve housing. Cupped side of seal must face valve housing, with seal lip facing away from valve housing.
8. Install pinion bearing in lower gear housing using tool No. T78P-3504-G, or equivalent, Fig. 11.
9. Apply lubricant C3AZ-19578-A, ESW-M1C87-A, or equivalent to pinion bushing, pinion bearing and pinion teeth.
10. Move rack to left stop, then install valve and valve housing assembly into gear housing bore. The flat on input shaft spline must be aligned with alignment mark placed on valve housing during disassembly.
11. Install valve housing to gear housing attaching bolts and washers and tighten bolts finger tight. Tighten bolts in rotation one turn at a time until pinion seal is seated and a torque of 10 to 15 ft. lbs. is obtained.
12. Install pinion shaft torque adapter T74P-3504-R, or equivalent, on input shaft splines.

Fig. 4 Pinion bearing locknut removal & installation. Capri, Fairmont, Mustang & Zephyr:





13. Install a new pinion bearing locknut on pinion shaft, Fig. 4. While holding input shaft, torque locknut to 23 to 34 ft. lbs. Rack should be away from stop when torquing locknut.
14. Install pinion bearing plug using a torque wrench and a 1{1-8} in. socket. Torque plug to 40 to 60 ft. lbs.
15. Install flare gaskets into line fittings on gear housing and valve housing. Install pressure lines and torque fittings to 10 to 15 lbs.
16. Install yoke plug locknut. Prior to torquing locknut, adjust rack yoke preload as described under ``Rack Yoke Bearing Preload Adjustment.'' Torque yoke plug locknut to 44 to 66 ft. lbs.

GEAR HOUSING, RACK YOKE BEARING, RACK ASSEMBLY, RACK BUSHING & OIL SEALS

Disassemble
1. Remove tie rods and sockets from both ends of rack, also remove input shaft and valve assembly as described previously.
2. Using tool No. T74P-3504-U, or equivalent remove yoke plug locknut. Remove yoke plug using tool No. T77P-3504-A, or equivalent, then remove yoke spring and bearing from gear housing.


Fig. 12 Rack bushing locknut removal or installation. Fairmont & Zephyr:




Fig. 13 Removing rack bushing lock ring. 1982 Capri, Mustang & 1984---86 Mustang SVO:




Fig. 14 Positioning inner rack oil seal remover. Capri, Mustang:




Fig. 15 Removing oil seal from rack bushing. Capri, Mustang:





3. Working from right side of gear, push rack until it bottoms.
4. On all models except 1982 Mustang, Capri and 1984---86 Mustang SVO, install rack bushing locknut tool T74P-3504-B, or equivalent, over exposed end of rack and into housing bore. Position tool so that two tabs engage in slots on rack bushing lock nut, then remove locknut, Fig. 12.
5. On 1982 Mustang, Capri and 1984---86 Mustang SVO, install rack bushing locknut tool T77P-3504-A, or equivalent, so the drive tabs engage the slots of lock ring, Fig. 13. Rotate tool counter clockwise to drive the lock wire out of slot of housing and remove lock ring.
6. Slowly pull rack out of housing until rack piston contacts rack bushing. Pull on rack until bushing is removed from housing, then remove rack.
7. Insert rack seal remover tool T74P-3504-C, or equivalent, into housing until it bottoms in housing, Fig. 14. Using a wrench, tighten tool until it is fully expanded. Attach a suitable slide hammer to tool and remove oil seal from housing.
8. Remove O-rings from rack piston.
9. Place rack bushing in holding tool T74P-3504-E, or equivalent, then position tool and bushing in a vise. Remove oil seal from bushing using tool No. T74P-3504-C, or equivalent, and a suitable slide hammer. Remove O-ring from bushing, Fig. 15.


Fig. 16 Inner rack oil seal installation. Capri, Mustang:




Fig. 17 Rack piston seal installation. Capri, Mustang:




Fig. 18 Positioning protective sleeves on rack. Capri, Mustang:





Assemble
1. Position oil seal on tool No. T74P-3504-D, or equivalent, with lip spring facing tool. With gear in vertical position, insert tool into right side bore of gear housing, Fig. 16. Tap handle of tool until seal bottoms in housing. Use care not to cock handle when installing seal. If tool binds in area of left turn pressure port, align flat on tool with pressure port. A scribed line on tool handle will aid in aligning flat with pressure port.
2. Install rubber O-ring in groove on rack piston.
3. Position plastic O-ring on tool No. T74P-3504-G, or equivalent, Fig. 17. Slide tool and O-ring onto rack until it is adjacent to rack piston, then slide O-ring off tool and into piston groove over rubber O-ring.
4. Apply lubricant C3AZ-19578-A, ESW-M1C87-A or equivalent to rack teeth and to rack surface that will contact protective sleeve T74P-3504-K, or equivalent.
5. Place protective sleeve T74P-3504-K, or equivalent, over rack teeth. The protective sleeve will prevent rack teeth from damaging the oil seal, Fig. 18.
6. Thread protective sleeve over threads on right side of rack, Fig. 18.
7. Lubricate plastic O-ring and protective sleeve with power steering fluid.
8. Install large end of tool No. T74P-3504-H, or equivalent, onto rack tooth end of rack. Position tool so that it compresses plastic O-ring properly.


Fig. 19 Installing rack into gear housing. Capri, Mustang:




Fig. 20 Rack bushing oil seal installation. Capri, Mustang:




Fig. 21 Installing rack bushing:




Fig. 22 Installing rack bushing lock ring. 1982 Capri, Mustang & 1984---86 Mustang SVO:





9. Position rack with gear toothed end first, into housing, until leading end of rack engages oil seal, Fig. 19. Position tool against housing so that plastic O-ring is aligned with housing bore. Push rack into housing until protective sleeve protrudes from left side of gear housing. Remove tools from rack and place ball socket on lefthand side of rack to prevent damage to oil seal.
10. Install rubber O-ring on rack bushing.
11. Using tool No. T74P-3504-F, or equivalent, install oil seal in rack bushing with lip spring facing bushing, Fig. 20.
12. Lubricate short protective sleeve on rack end and rubber O-ring on rack bushing with power steering fluid.
13. Position bushing on rack with seal facing outward. Push bushing and seal over protective sleeve and into housing bore until housing bore lock nut threads are visible. Remove protective sleeve, Fig. 21.
14. On all models except 1982 Mustang, Capri and 1984---86 Mustang SVO position rack bushing locknut over rack and start threading into gear housing. Engage tabs of tool No. T74P-3504-B, or equivalent, into slots on locknut, Fig. 12. Then torque locknut to 80 to 120 ft. lbs.
15. On 1982 Mustang, Capri and Mustang SVO, position rack bushing lock ring over the rack into the housing bore, Fig. 22. Position lock ring tool T-77P-3504-A, or equivalent, over the end of the rack and engage the slots of lock ring. Rotate lock ring until wire groove is positioned at the slot in housing and engage retaining wire. Rotate the lock ring until the wire is fully engaged and wire end is 180 degrees opposite the slot.
16. Install tie rod ball sockets as described previously.
17. Install input shaft and valve assembly as described under ``Valve and Valve Housing.''
18. Install yoke bearing, spring, plug and locknut. Prior to torquing locknut, adjust yoke bearing preload as described under Rack Yoke Bearing Preload Adjustment.
19. Install bellows and tie rod ends.

DISASSEMBLE
On some models, a power steering pressure switch is installed in the power steering pressure line. The purpose of this switch is to activate the throttle kicker during periods of high power steering pump pressure, such as parking. On vehicles equipped with air conditioning the power steering pressure switch will also open the air conditioning clutch circuit.



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