Assembly
1. Lubricate the sector shaft seal bore.
- Use Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-A and ESR-M1C159-A.
2. Use Sector Shaft Seal Replacer to install the sector shaft seal.
- Lubricate the sector shaft seal.
- Use Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-A and ESR-M1C159-A.
3. Install the spacer.
4. Install the snap ring.
5. Use Sector Shaft Seal Replacer to install the steering gear sector shaft dust seal.
- Lubricate the steering gear sector shaft dust seal, use Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specification ESB-M1C93-B and ESR-M1C159-A.
NOTE: Place the steering gear sector shaft housing oil seal on Sector Shaft Seal Replacer so the raised lip is toward the tool.
6. Remove the steering gear housing from the Bench Mounted Holding Fixture.
7. Position the input shaft bearing in the valve housing and use Input Shaft Bearing Seal Tool Set and a press to seat the bearing.
8. Use Input Shaft Bearing Seal Tool Set and a press to seat the input shaft seal.
9. Install the input shaft snap ring.
10. Use Input Shaft Bearing Seal Tool Set to install the input shaft dust seal.
11. Mount the valve housing in Bench Mounted Holding Fixture.
12. Install the input shaft and control into the valve housing.
13. Position the power steering gear race nut into the valve housing.
14. Use Adjuster and Locknut Wrench to tighten the power steering gear race nut.
15. Install the setscrew.
16. Remove the valve housing from Bench Mounted Holding Fixture and position the piston on the worm gear.
17. Install the steering gear ball return guide on the piston.
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.
18. Rotate the piston while holding the steering gear ball return guide and install the 28 ball bearings into the opening in the ball guide.
WARNING:
- THE CORRECT NUMBER OF BALLS IS REQUIRED FOR PROPER GEAR OPERATION. COUNT THE BALLS AND INSERT EACH CAREFULLY.
- TO MAKE SURE THE BALLS ARE PROPERLY 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.
19. Install the ball return guide clamp.
(1) Position the ball return guide clamp.
(2) Install the bolts.
20. Install a new gasket.
21. Lubricate and install the piston seal on the piston.
- Use Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specification ESB-M1C93-B and ESR-M1C159-A.
22. Install the piston assembly into the gear housing.
NOTE: Make sure to align the oil passages in the gear housing.
23. Rotate the teeth so they are on the same plane as the sector shaft.
24. Loosely install the four valve housing bolts.
- If so equipped, install the identification tag.
25. Lubricate the O-ring on the sector shaft housing cover.
- Use Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specification ESB-M1C93-B and ESR-M1C159-A.
26. Rotate the housing clockwise and install the sector shaft into sector shaft housing.
27. Install the sector shaft lock nut.
NOTE: The sector shaft lock nut will be tightened during steering gear meshload adjustment.
28. Install the sector shaft housing assembly.
NOTE: Loosely install the sector shaft housing bolts.
29. Tighten the four sector shaft housing bolts.
30. Tighten the four valve housing bolts.