Power
Fig. 23 Disassembled view of TRW power rack & pinion steering gear. Escort, EXP, LN7, Lynx, Tempo & Topaz:
Fig. 27 Removing tie ball socket retaining pin with an easy-out. Escort, EXP, LN7, Lynx, Tempo & Topaz:
Fig. 28 Removing tie ball retaining pin using tool T78P-3504-N. Escort, EXP, LN7, Lynx, Tempo & Topaz:
Fig. 29 Tie rod ball socket removal & installation. Escort, EXP, LN7, Lynx, Tempo & Topaz:
TIE ROD BALL SOCKETS
Disassemble
1. Mount power steering in a vise, clamping only by the steel tube section between the rack pressure ports.
2. Remove tie rod ends and jam nuts, Fig. 23. Mark position of tie rod ends on tie rod for reassembly.
3. Remove bellow clamps, bellows and breather tube. Use care not to damage bellows.
4. Using an easy-out, Fig. 27 or tool No. T78P-3504-N, Fig. 28, 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. T81P-3504-G, or equivalent, a torque wrench and a crescent wrench to hold the rack from rotating, Fig. 29.
Fig. 29 Tie rod ball socket removal & installation. Escort, EXP, LN7, Lynx, Tempo & Topaz:
Fig. 30 Installing power rack & pinion bellows. Escort, EXP, LN7, Lynx, Tempo & Topaz:
Assemble
1. Install and tighten tie rod ball sockets hand tight.
2. Using a crescent wrench to prevent rack from rotating, tighten lefthand ball socket to a torque of 50 to 55 ft. lbs. using tool No. T81P-3504-G, or equivalent, Fig. 29. If rack is not restrained from rotating, damage to rack or pinion teeth may result.
3. Install spiral pin for lefthand socket using a pair of pliers and a small hammer.
4. Restrain lefthand tie ball socket from turning while tightening righthand 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, secure clamps properly, Fig. 30.
6. Install tie rod ends and jam nuts.
Fig. 24 Adjusting yoke plug. Escort, EXP, LN7, Lynx, Tempo & Topaz:
Fig. 25 Yoke plug locknut removal & installation. Escort, EXP, LN7, Lynx, Tempo & Topaz:
Fig. 31 Removing & installing pinion bearing locknut. Escort, EXP, LN7, Lynx, Tempo & Topaz:
Fig. 32 Removing valve assembly, input shaft seal & bearing. Escort, EXP, LN7, Lynx, Tempo & Topaz:
INPUT SHAFT & VALVE ASSEMBLY
Disassemble
1. Thoroughly clean rack and pinion assembly and mount in a vise, clamping only by the steel tube section between the rack pressure ports.
2. Do not remove the external pressure lines unless damaged or leaking. If the lines are removed the copper seals must be replaced.
3. Using tool No. T81P-3504-G, or equivalent, loosen yoke plug locknut, Fig. 25, remove yoke plug with tool No. T81P-3504-U, or equivalent, Fig. 24, lift out spring and yoke.
4. Remove power steering gear housing cap.
5. Position tool No. T81P-3504-R, or equivalent, on input shaft. While holding input shaft, remove pinion bearing locknut using a suitable 17 mm socket, Fig. 31. Discard locknut.
6. Remove input shaft seal snap ring.
7. Position input shaft and valve body puller tool No. T81P-3504-T, or equivalent, on input shaft, Fig. 32. Using a suitable wrench, turn nut to remove input shaft, valve body, input shaft seal and bearing.
Fig. 33 Positioning lower pinion shaft seal remover. Escort, EXP, LN7, Lynx, Tempo & Topaz:
Fig. 34 Activating tool expander. Escort, EXP, LN7, Lynx, Tempo & Topaz:
Fig. 35 Removing lower pinion shaft seal. Escort, EXP, LN7, Lynx, Tempo & Topaz:
8. Remove the lower pinion shaft seal using protective sleeve tool T78P-3504-E, or equivalent. Insert the tools into the gear housing. Using a plastic mallet, tap the tool lightly to seat it, Fig. 33. Activate the tool expander, Fig. 34.
9. Using a slide hammer tool No. T50T-100-A, or equivalent, remove seal then tools, Fig. 35.
10. Position a suitable expanding type puller over the gear housing and remove pinion bearing. Remove the pinion bearing only if damaged.
11. If the valve assembly plastic seal rings are to be replaced use a sharp pocket knife to cut them off. Use care not to scratch or nick the valve sleeve.
Fig. 36 Installing pinion bearing. Escort, EXP, LN7, Lynx, Tempo & Topaz:
Fig. 37 A---F Valve assembly sleeve ring installation sequence. Escort, EXP, LN7, Lynx, Tempo & Topaz:
Assemble
1. Support the valve housing on a clean flat surface. Using tool No. T81P-3504-H, or equivalent, install new pinion bearing, Fig. 36.
2. With the valve housing supported as in step 1, apply grease to a new pinion oil seal. Using a suitable seal installer, position the pinion oil seal on the installer with seal lip towards tool and install in valve housing, seating seal against shoulder.
3. Install four valve sleeve rings, refer to Fig. 37 A---F and the following steps:
a. Lubricate sleeve tool No. T81P-3504-M1, or equivalent, with automatic transmission fluid type F or equivalent, position tool over valve assembly, Fig. 37A.
b. Place valve sleeve ring over tool, quickly push down on pusher tool No. T81P-3504-M2, or equivalent, sliding the ring down into the fourth groove, Fig. 37B.
c. Using automatic transmission fluid type F, lubricate inside of sizing tool T81P-3504-M3, or equivalent, slowly work the tool over the installed ring to seat it. Take care not to deform the ring. Repeat this step after each ring is installed, Fig. 37C.
d. Position spacer tool No. T81P-3504-M4, or equivalent, over input shaft with the thin lip toward the input shaft splines. This aligns the sleeve tool No. T81P-3504-M1, or equivalent, with the third groove, Fig. 37D, repeat steps a, b and c above.
e. Position the second spacer tool with the lip toward the input shaft splines, Fig. 37E. Repeat steps a, b and c above.
f. Remove the second spacer and turn it over so the thin lip of the second spacer contacts the thin lip of the first spacer, Fig. 37F. Repeat steps a, b and c above.
4. Remove tools from input shaft and valve assembly, carefully inspect sleeve rings to ensure they are seated correctly and turn freely in their grooves.
5. Position rack in rack housing with three rack teeth protruding from left side of housing. Carefully observe rack while looking through valve housing bore and center the visible rack tooth in the valve bore.
Fig. 38 Installing valve assembly. Escort, EXP, LN7, Lynx, Tempo & Topaz:
Fig. 39 Installing input shaft bearing. Escort, EXP, LN7, Lynx, Tempo & Topaz:
Fig. 31 Removing & installing pinion bearing locknut. Escort, EXP, LN7, Lynx, Tempo & Topaz:
Fig. 25 Yoke plug locknut removal & installation. Escort, EXP, LN7, Lynx, Tempo & Topaz:
6. Insert sizing tool No. T81P-3504-M3, or equivalent, into valve housing. Position ``D'' flat on input shaft at the 3 o'clock position and carefully install valve assembly into housing, Fig. 38.
7. Check to ensure that pinion is centered, turn input shaft with a suitable tool and count the number of turns from pinion shaft center to each steering stop. If the number of turns is unequal, pull out the valve assembly and repeat steps 5 and 6. If still unequal, pull the valve assembly out far enough to free the rack and pinion gears and rotate pinion gear 60° (one tooth). Reassemble, retest and repeat procedure if necessary.
8. Using tool No. T81P-3504-R, or equivalent, install input shaft bearing, wide face up in valve bore, Fig. 39.
9. Holding input shaft with a suitable tool install a new locknut on pinion end shaft. Torque locknut to 20 to 35 ft. lbs., Fig. 31. This operation must be performed with the rack near center position.
10. Install input shaft seal protector tool No. T81P-3504-P, or equivalent, over input shaft, apply a film of gear lube part No. C3AZ-19578-A or equivalent to the input shaft seal and install seal with lip spring facing valve assembly.
11. Install input shaft seal retaining snap ring.
12. Install power steering gear housing cover torque to 35 to 55 ft. lbs.
13. Fill yoke housing with 2 ounces of gear lubricant part No. C3AZ-19578-A or equivalent, install yoke.
14. Install yoke thrust spring and yoke plug. Refer to ``Rack Bearing Preload Adjustment.'' Install yoke plug locknut and torque to 40 to 50 ft. lbs. while holding yoke plug in position, Fig. 25.
15. If the external pressure lines were removed during disassembly they must be replaced using new copper seals. Crimp copper seals to the lines with pliers using caution not to damage the exterior of the seals. Do not drop the seals into pressure ports as they may misalign.
Fig. 13 Removing rack bushing lock ring. 1982 Capri, Mustang & 1984---86 Mustang SVO:
Fig. 40 Positioning internal rack seal removal tool. Escort, EXP, LN7, Lynx, Tempo & Topaz:
Fig. 41 Removing internal rack seal. Escort, EXP, LN7, Lynx, Tempo & Topaz:
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, valve assembly and rack yoke as described previously.
2. Working from the right side of gear, push in rack until it bottoms. Position rack bushing lock ring tool No. T77P-3504-A, or equivalent, over exposed end of rack and engage socket drive tabs in end plate slots, rotate tool clockwise until the end of the retainer wire is visible in the tube slot, turn tool counterclockwise and using an icepick or similar tool, start the retainer wire out of the slot and remove, Fig. 13.
3. Pull the rack, end plate, rack bushing and rack piston out the right side of housing. If rack, end plate, rack bushing and rack bushing assembly are difficult to remove, install tie rod hand tight on rack assembly, then install slide hammer weight over tie rod. Install a nut on tie rod to slide weight against, and use the weight and tie rod assembly as a slide hammer to remove rack assembly.
4. Insert internal rack seal remover tool No. T81P-3504-B, or equivalent, into housing bore, tap tool with plastic mallet until it bottoms, Fig. 40. Using a suitable wrench, tighten tool until fully expanded. Attach slide hammer and remove seal and nylon back up ring, Fig. 41.
Fig. 42 Removing oil seal from rack bushing. Escort, EXP, LN7, Lynx, Tempo & Topaz:
Fig. 43 Rack bushing O-ring removal. Escort, EXP, LN7, Lynx, Tempo & Topaz:
5. Cut off rack piston seal ring and remove back up O-ring with a small pointed tool.
6. Insert rack bushing in holding tool T81P-3504-D, or equivalent, seal end first. Place tool and bushing in a vise, using tool T81P-3504-A, or equivalent, and a suitable slide hammer remove seal, Fig. 42.
7. Remove rack bushing O-ring by pushing it to one side with fingertips, then roll the O-ring over and remove, Fig. 43.
Fig. 44 Rack bushing seal installation. Escort, EXP, LN7, Lynx, Tempo & Topaz:
Fig. 45 Rack piston, seal & O-ring installation. Escort, EXP, LN7, Lynx, Tempo & Topaz:
Fig. 46 Protective sleeve installed on rack. Escort, EXP, LN7, Lynx, Tempo & Topaz:
Assembly
1. Using rack oil seal replacer tool No. T81P-3504-C, or equivalent, apply power steering fluid to inner rack seal and position seal on tool, seal lip facing tool, Fig. 44. Insert sizing tool T81P-3504-K, or equivalent, in end of rack tube, position seal replacer in sizing tool and carefully push in by hand until bottomed, tap the tool with a plastic hammer to seat the seal, leaving sizing tool installed in rack.
2. Position rack piston seal installer tool No. T81P-3504-L, or equivalent, on rack as shown in Fig. 45, slide rubber O-ring over the tool into piston groove then slide plastic seal ring over tool into piston groove on top of the O-ring.
3. Apply fluid grease C3AZ-19578-A, or equivalent to rack teeth and position long protective sleeve tool No. T81P-3504-J, or equivalent, over the rack gear teeth, Fig. 46.
4. Lubricate piston seal ring and protective sleeve tool with power steering fluid.
Fig. 47 Outer rack oil seal installation. Escort, EXP, LN7, Lynx, Tempo & Topaz:
Fig. 48 Outer rack oil seal & bushing, disassembled. Escort, EXP, LN7, Lynx, Tempo & Topaz:
Fig. 49 Installing nylon ring in oil seal. Escort, EXP, LN7, Lynx, Tempo & Topaz:
Fig. 50 Installation sequence, rack bushing, seal, nylon ring & end plate. Escort, EXP, LN7, Lynx, Tempo & Topaz:
5. Position rack in rack sizing tool, carefully push rack into the housing and through rack internal oil seal. Ensure the sizing tool is properly positioned to compress and guide the plastic seal ring into housing bore. Push rack in until the protective sleeve protrudes from left side of gear, remove tools and install lefthand tie rod assembly hand tight.
6. Apply gear lube to outer rack oil seal, install oil seal in rack bushing with outer rack oil seal replacer, Fig. 47. Lip spring must face the inside of the bushing, Fig. 48. Install nylon ring in oil seal, Fig. 49.
7. Install outer rack bushing O-ring.
8. Position short protective sleeve tool No. T81P-3504-N, or equivalent, over right side tie ball socket threads, apply automatic transmission fluid to protective sleeve tool and rack bushing O-ring.
9. Position rack bushing with seal and nylon ring facing out on protective sleeve, Fig. 50. Slide the rack bushing over the sleeve into housing bore, place end plate against the rack bushing with drive slots facing out. Remove protective sleeve.
Fig. 22 Installing rack bushing lock ring. 1982 Capri, Mustang & 1984---86 Mustang SVO:
10. Using lock ring wrench tool No. T77P-3504-A, or equivalent, with drive tabs engaged in the end plate slots, push in end plate until end plate retainer wire groove is visible through the rack cylinder slot. Rotate end plate to line up the retainer wire hole with the cylinder slot, insert bent end of the retainer wire in the wire hole and rotate end plate clockwise until the retainer wire is fully engaged. Turn an additional 180 degrees, Fig. 22.
11. Install tie rod ball sockets as described previously.
12. Install input shaft and valve assembly as described previously.
13. Install yoke bearing, spring, plug and locknut. Prior to torquing locknut, adjust yoke bearing preload as described under ``Rack Yoke Bearing Preload Adjustment.''
14. Install bellows and tie rod ends.