Removal and Installation
Special Service Tool(s) Required
Tool Number Description
T94T-6000-AH Exhaust Connector Holder Tool
T57L-500-B Bench Mounted Holding Fixture
Removal
1. Disconnect negative battery cable.
2. Position steering wheel one-half turn to right and lock wheel.
3. Position steering column boot out of the way.
Remove pinch bolt retaining steering column intermediate shaft coupling to power steering short rack and separate.
4. Disconnect PCV vent tube and vacuum supply hose from clean air tube.
Loosen two hose clamps retaining clean air tube and position out of the way.
5. Disconnect power steering auxiliary actuator and power steering pressure switch.
6. Remove two heat shield pushpin retainers from power steering hose bracket and remove heat shield.
7. Remove one retaining bolt from left turn pressure hose bracket.
8. Position drain pan under steering gear.
9. Remove power steering pressure and return hoses from fittings on power steering rack.
Position both hoses out of the way.
Disconnect rear HO2S connector at steering rack and position out of the way.
10. Partially raise vehicle.
11. Remove front wheel and tire assemblies.
12. Remove LH upper stabilizer bar link retaining nut and position link out of the way.
13. Loosen LH tie-rod jam nut.
Remove cotter pin and tie-rod retaining nut at lower control arm.
Using tie-rod end separator or equivalent, remove tie-rod from control arm and from steering gear.
14. Loosen RH tie-rod jam nut.
Remove cotter pin and tie-rod retaining nut at lower control arm.
Using tie-rod end separator or equivalent, remove tie-rod from control arm and from steering gear.
15. Raise vehicle.
16. Remove drain pan.
17. Remove two steering gear retaining nuts at front subframe.
18. Install Exhaust Connector Holder Tool T94T-6000-AH on flex tube.
19. Remove bolts, nuts, and gasket from where flex tube and converter Y-pipe connect.
Separate tube from pipe.
20. Position Rotunda Power Train Lift 014-00765 or equivalent with wood blocks approximately 1 meter (39 inches) in length (secured to lift) under subframe and raise.
21. Remove two rear subframe retaining bolts and lower subframe approximately 102 mm (4 inches).
22. Rotate power steering rack to clear bolts from subframe and remove assembly through LH wheel well.
23. Remove two bolts retaining power steering hose bracket to short rack and remove bracket.
24. Mount steering gear assembly in Bench Mounted Holding Fixture T57L-500-B.
25. Remove four clamps retaining bellows to steering gear and tie-rods.
Remove bellows and power steering gear rack tube.
26. Position rack and pinion steering gear so several steering gear teeth are exposed.
Hold steering gear with adjustable wrench on end teeth only, while loosening inner tie-rods.
Remove tie-rods from steering rack.
Remove steering rack from bench-mounted holding fixture.
Power Rack and Pinion Steering Gear Components
Variable Assist Power Steering, System Components
Installation
1. Mount new steering gear assembly in Bench Mounted Holding Fixture T57L-500-B.
2. Position rack and pinion steering gear so several steering gear teeth are exposed.
Hold steering gear with adjustable wrench on end teeth only, while tightening inner tie-rods.
Tighten to 90-110 Nm (66-81 ft-lbs.).
3. Apply Steering Gear Grease C3AZ-19518-A meeting Ford specification ESB-M1C119-A to groove in connecting rods where tie-rod bellows clamp to front wheel spindle tie-rod and uniformly apply to inner diameter of bellows.
Install bellows and gear rack tube onto short rack.
4. Install new inner and outer bellows clamps.
5. Remove steering gear from Bench Mounted Holding Fixture and place on bench.
6. Install power steering hose bracket and retaining bolts at top of steering gear.
Tighten to 9-12 Nm (80-106 in-lbs.).
7. Install steering gear retaining bolts in steering gear housing and install short rack through LH wheel well.
8. Position steering rack and retaining bolts through subframe.
Raise powertrain lift until rear subframe contacts body and install retaining bolts.
Tighten to 135-195 Nm (100-144 ft-lbs.).
Lower and remove powertrain lift from vehicle.
9. Install power steering short rack-to-subframe nuts.
Tighten to 97-132 Nm (72-97 ft-lbs.).
10. Install new gasket, bolts and nuts at converter Y-pipe and flex tube.
Tighten to 34-46 Nm (26-34 ft-lbs.).
11. Remove flex tube holder.
12. Partially lower vehicle.
13. Install LH jam nut and outer tie-rod to inner tie-rod.
Install tie-rod to steering knuckle.
Install retaining nut.
Tighten to 47-63 Nm (35-46 ft-lbs.).
Install new cotter pin.
14. Install LH stabilizer bar link and retaining nut.
Tighten to 76.5-103.5 Nm (57-76 ft-lbs.).
15. Install RH jam nut and outer tie-rod to inner tie-rod.
Install tie-rod to steering knuckle.
Install retaining nut.
Tighten to 47-63 Nm (35-46 ft-lbs.).
Install new cotter pin.
16. Install tire and wheel assemblies.
Tighten to 115-142 Nm (85-105 ft-lbs.).
17. Lower vehicle.
18. Remove old Teflon (TM) O-rings from pressure and return hoses.
Install new Teflon (TM) O-rings on pressure and return hoses.
19. Install power steering pressure hose and return hose to fittings on power steering short rack.
Tighten to 33-41 Nm (24-30 ft-lbs.).
20. Install one retaining bolt to left-turn pressure hose bracket.
Tighten to 9-12 Nm (80-106 in-lbs.).
21. Connect rear HO2S connectors, power steering auxiliary actuator, and power steering pressure switch electrical connectors.
22. Position heat shield at power steering hose bracket and install pushpin retainers.
23. Install clean air tube, connect PCV vent tube and vacuum supply hose, and tighten hose clamps.
Tighten to 2-3 Nm (18-27 in-lbs.).
24. Install steering column intermediate shaft coupling to power steering short rack and install pinch bolt.
Tighten to 41-51 Nm (30-38 ft-lbs.).
Position steering column boot over steering rack.
25. Fill and purge system.
26. Check operation.
27. Adjust only toe for alignment.