Steering Rack - New Service Procedure

85ford01 Article No. 85-1-12
STEERING - POWER - NEW SINGLE DIAMETER RACK DESIGN SERVICE PROCEDURE
FORD 1985 LTD, MUSTANG, T-BIRD, MUSTANG SVO

LINCOLN-MERCURY 1985 MARQUIS, CAPRI, COUGAR, MARK VII, CONTINENTAL

The power steering gear used on the subject vehicles incorporates a new single diameter rack design starting in approximately November of 1984. "Single Diameter" means that the diameter at the rack teeth is the same as the rest of the rack shaft. The new rack also has a wider piston.
When servicing the steering gear with this new rack, a new rack seal protector is required, along with a new procedure for installing the inner rack seal and the rack assembly. The new rack seal protector, T85L-3504-B, is part of the 1985 Essential Tool Package.

Figure 9:

Use the following steps along with the 1985 Shop Manual, Section 13-46, Assembly Procedure, starting on page 13-46-19.

1. Rack oil seal replacer tool T78P-3504-K is not required. Skip Step 1 on page 13-46-20.
2. Perform Steps 2, 3, and 4 of the Shop Manual.
3. Remove the plastic insert (Figure 9) from the rack seal. Save the insert for reinstallation.

Figure 10:

Figure 11:

Figure 12:

Figure 13:

4. Install the rack seal protector, tool T85L-3504-B, over the rack teeth. This is not the same as the tool shown in the 1985 Shop Manual. (Figure 10).
5. Lubricate the rack seal protector and rack with power steering fluid.
6. Install the seal with the lip toward the piston (Figure 10). Push the seal all the way against the piston. Remove the rack seal protector.
7. Install the plastic insert in the rack seal (Figure 11).
8. Pack rack teeth with steering gear lubricant (Figure 12). Apply a light coat of steering gear lubricant to the yoke contact area, back of the rack teeth.
9. Lubricate the piston seal and rack seal outside diameter with power steering fluid (Figure 11).
10. Install sizing tool T78P-3504-M into the end of the gear housing (Figure 13).

Figure 13:

11. Install the rack, taking care NOT to scratch the housing piston bore (Figure 13).
12. Carefully push the piston through the sizing tool (Figure 13). Continue pushing on the rack until it bottoms. Remove sizing tool.

Figure 14:

13. Seat the rack seal with the rack by driving the end of the rack with a drift or bar stock and plastic mallet (Figure 14). DO NOT remove the rack.
14. Move the rack so it is approximately centered in the housing.
15. Thread the short protective sleeve, Tool T74P- 3504-J, over the threads on the right side of the rack (Step 6 of the Shop Manual). Apply power steering fluid to the protective sleeve.
16. Proceed with Shop Manual instructions starting with Step 10, page 13-46-22.

OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: "INFORMATION ONLY"