Disassembly and Assembly
DISASSEMBLY1. On models equipped with airbag, disarm airbag system.
2. On models less airbag, disconnect battery ground cable, then unsnap horn cover from steering wheel by grasping the sides of the horn cover and pulling toward yourself.
3. Disconnect the horn/speed control wire harness connector from the contact assembly, then remove horn cover from steering wheel.
4. Remove steering wheel retaining bolt.
5. Install Steering Wheel Puller tool No. T67L-3600-A or equivalent, then remove steering wheel from column.
6. On models equipped with airbag, remove four airbag retaining nuts from back side of steering wheel, then lift airbag module away from steering wheel.
7. Disconnect airbag wire harness connector, then remove airbag from steering wheel. To avoid personal injury, always carry module with airbag deployment door facing away from body. Set airbag module on workbench with deployment door facing upward.
8. Install Steering Wheel Puller tool No. T67L-3600-A or equivalent, then remove steering wheel from column. Route contact assembly wire harnesses through steering wheel as wheel is lifted off shaft.
9. Remove steering column as previously outlined.
10. Remove lower U-joint, spring sensor ring and bushing.
Fig. 12 Exploded View of Steering Column:
Fig. 11 Lower Bearing Retainer:
Fig. 14 Removing Upper Ring And Coil Spring:
11. Remove turn signal cancelling cam by pushing up with a flat-bladed screwdriver. Note position of flush surface, Figs. 12 and 13.
12. Remove steel sleeve and ring, Fig. 14, then ignition switch retaining screws and switch assembly from column.
13. On Aerostar models, remove brake/shift interlock solenoid retaining screws, then solenoid assembly from column.
Fig. 15 Removing Shift Control Assembly:
Fig. 16 Actuator Cam Pivot Pin Removal:
Fig. 17 Plastic Bearing Retainer:
14. On all models, remove shift control assembly and shift control bracket (column shift only), Fig. 15.
15. Using a drift, tap actuator cam pivot pin loose, Fig. 16. Remove with diagonal pliers.
16. Remove plastic bearing retainer from lock cylinder bore, Fig. 17.
Fig. 18 Ignition Lock Gear Metal Bearing:
Fig. 19 Tilt Pivot Bolts:
Fig. 20 Column Lock Actuator:
Fig. 23 Installing Lower Bearing Retainer:
Fig. 22 Removing Of Tilt Position Lever Pivot Pin:
17. Remove metal bearing from lock cylinder bore, Fig. 18, then ignition lock gear.
18. Remove two pivot bolts, Fig. 19. Use caution as tilt spring will release when bolts are removed. Remove lock cylinder housing.
19. Remove steering shaft from column assembly, then column lock actuator, Fig. 20.
20. Remove lower bearing retainer and mounting bracket, Fig. 21.
21. Using a punch, remove tilt position lever arm pivot pin, Fig. 22. Remove lever lock arm and spring.
ASSEMBLY
Fig. 23 Installing Lower Bearing Retainer:
Fig. 24 Sensor Ring And Related Components:
Fig. 25 Actuator Cam Installation Location:
Fig. 26 Tilt Lever Spring Installation:
Fig. 27 Tilt Pivot Bolt Lubrication Locations:
1. Install steering shaft into housing.
2. Install lower bearing retainer and column mounting bracket, Fig. 23. Torque retaining screws to 5-8 ft. lbs.
3. Install sensor ring, bushing, spring and flex coupling (if separated from intermediate steering shafts) to steering shaft, Fig. 24.
4. Lubricate lock actuator assembly with part No. ESA-M1C232-A grease or equivalent prior to installation. Position lock actuator assembly in housing.
5. Position actuator cam in lock housing, then install cam pivot pin with small hammer. Tap pin in until flush with housing, Fig. 25.
6. Install tilt lever spring and arm into housing using a punch to hold in place, Fig. 26. Tap pin into place while driving out punch.
7. Support housing in a soft jawed vise, then drive pin flush with housing.
8. Place two nuts or washers between tilt lock levers and housing to separate tilt lock arms from housing.
9. Lubricate pivot bolts, Fig. 27, with part No. ESA-M1C232-A grease or equivalent before installing.
10. Position tilt spring on lock housing. With help from an assistant, install lock housing and pivot bolts. Torque pivot bolts to 14-19 ft lbs.
Fig. 28 Steel Sleve And Ring Installation:
Fig. 29 Snap Ring Installation:
Fig. 30 Turn Signal Cancel Cam Installation:
Fig. 31 Ignition Switch Index Mark:
11. Install steel sleeve and ring over steering shaft to upper bearing as shown in Fig. 28.
12. Install spring and new snap ring on top side of spring using a 3/4 inch by 2-1/4 inch piece of PVC pipe as shown in Fig. 29.
13. Install turn signal cancel cam, flush surface face up, Fig. 30.
14. Install ignition switch. Align pin from switch with slot in lock/column assembly. Position slot in lock/column assembly with index mark on casting as shown in Fig. 31. Ignition switch should be in the RUN position. Torque two retaining screws to 5-8 ft. lbs.
15. Coat ignition gear and metal bearing with grease part No. ESA-M1C232-A or equivalent, then install ignition lock gear into lock housing.
16. Install metal bearing into lock housing, then plastic bearing retainer.
17. Install shift control tube assembly (column shift only). Coat bushings with specified grease. Torque retaining screws to 5-8 ft. lbs.
18. On Aerostar models, install brake/shift interlock solenoid.
19. On all models, install steering column and steering wheel assembly as previously outlined in this section.