Steering Gear - Simplified Valve Seal Service
Article No. 85-6-5STEERING GEAR - TRW POWER - SIMPLIFIED VALVE SEAL SERVICE
FORD 1981-1985 ESCORT, EXP, TEMPO
LINCOLN-MERCURY 1981-1985 LYNX, LN7, TOPAZ
Ford Service Engineering continues to receive reports from fleets and retail customers of high costs for overrepairs on TRW rack and pinion steering gear pinion seal leaks on 1981-1985 Escort/Lynx, EXP/LN7, and 1984 Tempo/Topaz. Repairs for pinion seal leaks on TRW gears are apparently being confused with Owner Notification Program M24 which concerned pinion bore wear on Ford manufactured gears installed in vehicles other than the subject car lines. Because of this confusion, some dealers are replacing TRW steering component parts unnecessarily. Technical Service Bulletin 83-12-4 previously outlined an "on the car" valve seal service procedure for replacing the lower pinion seal.
Figure 7 - Proper Seal Positioning:
Most of the TRW gears returned to Engineering for evaluation as "unsealable" are found to have the seal installed backwards. The following illustration (Figure 7) shows the proper seal position on the installer tool -Part Number T84P-3504-F. The instruction sheet with the tool states that the seal should be installed with the garter spring towards the tool. Proper installation of
the seal, using the "on the car" procedure, will reduce repeat repairs and will reduce the cost of repair to an acceptable level. The following procedure is being republished for your convenience.
PROCEDURE:
Disassembly
1. Set the steering in straight ahead position and lock steering column.
2. Raise vehicle on hoist.
3. Remove bellows clamps and slide below outboard from gear housing. Thoroughly drain and wipe any fluid from boots.
4. Remove pinion cap. With column locked, remove pinion nut.
5. Place drain pan on floor below pinion area and lower vehicle.
6. From inside vehicle, remove column boot from dash panel, and disconnect intermediate shaft from gear (it may be necessary to loosen steering column to separate intermediate shaft from the steering gear).
7. Turn gear input shaft to the "on center" position so that D-flat is in the 3 o'clock position and road wheels are straight ahead.
Figure 3 - REMOVING/INSTALLING SNAP RING:
8. Remove snap ring retaining the shaft seal from the gear housing. (Figure 3).
CAUTION: Before proceeding to Step 9, protect carpeting inside car from oil spillage with rags or cardboard funnel. A small amount of fluid may come out from underneath the input shaft seal.
Figure 4 - REMOVING VALVE ASSEMBLY:
9. Attach input shaft and valve body puller (Tool T81P-3504-T or equivalent) to input shaft (Figure 4). Turn nut to remove valve assembly. Input shaft seal and bearing will come out with the valve body.
Figure 5 - Seating Pinion Seal Remover:
10. To remove the lower pinion shaft oil seal, insert protective sleeve (Tool T81P-3504-E or equivalent) along with T78P-3504-E or equivalent into the gear housing. Tap the tool with a plastic mallet to bottom it. (Figure 5).
Figure 6 - ACTIVATE EXPANDER IN PINION SEAL:
Activate the expander (Figure 6) by holding the large nut and turning the small nut until fully expanded.
11. Pull tool and seal out with large groove joint pliers. Oil will drain out through valve bore.
Figure 8 - INSTALLING PINION OIL SEAL:
Assembly
1. Apply power steering fluid to pinion oil seal and place on installation Tool T84P-3504-F or equivalent with seal lip towards tool (Figure 7). Install seal in valve bore, seating it against shoulder (Figure 8).
NOTE: To protect the seal outer diameter from the sharp edge of the step inside the valve bore, use sizing Tool T81P-3504-M3 or equivalent as a guide with its small diameter end in the valve bore.
2. Remove input shaft seal and bearing from valve assembly. Wipe oil from pinion gear teeth and regrease with steering gear grease Part No. C3AZ-19578-A (EDW-M1C87-A).
Figure 9 - INSTALLING VALVE ASSEMBLY:
3. Insert valve sizing tube (Tool T81P-3504-M3 or equivalent) into valve housing. Position the D-flat on the input shaft to the right and vertically (3 o'clock position) and insert valve assembly in the bore (Figure 9).
NOTE: The D-flat surface must be in the 3 o'clock position in the vehicle with the gear on center (straight ahead position). Rotate input shaft slightly, if necessary, to mesh the pinion with the rack teeth. Push valve assembly in by hand until seated properly. Remove sizing tool.
4. With wheels off the floor, using Tool T81P-3504- R or equivalent to turn input shaft, check if pinion is centered by counting the number of turns from center to each stop (approximately 1-1/2 turns). If the number of turns is unequal, pull valve assembly out far enough to free the pinion teeth. Rotate input shaft 60 degrees (one tooth) in the direction which required less turns. Reinsert valve assembly and check if on center. Repeat procedure if not on center.
Figure 10 - INSTALLING INPUT SHAFT BEARING:
Figure 11 - SEATING BEARING OR INPUT SHAFT SEAL:
5. Install input shaft bearing with wide face of case outward (Figure 10) in valve bore. Seat with Tool T81P-3504-R or equivalent by tapping end with plastic mallet (Figure 11).
Figure 12 - Tool T81P-3504-P:
6. Install input shaft seal protector (Tool T81P-3504-P or equivalent) over input shaft. Apply a film of gear lube (Part No. C3AZ-19578-A) to the input shaft seal and install with lip spring toward valve (Figure 12). Remove seal protector from input shaft and seat seal with Tool T81P-3504-R or equivalent (Figure 12).
Figure 3 - REMOVING/INSTALLING SNAP RING:
7. Install retaining snap ring in valve bore. (Figure 3).
8. Reconnect intermediate shaft to gear assembly and tighten pinch bolts to specification. Tighten steering column mounting bolts if column was loosened.
9. Install column boot to dash panel and tighten screws to specification.
10. With steering wheel locked, install new locknut on pinion end of valve assembly. Tighten the locknut to specification. The rack must be away from the stops during this operation.
11. Install steering gear housing cap and tighten to specification.
12. Install bellows and bellows clamps.
NOTE: Tie rod ends will have to be separated from spindles to install new clamps.
13. Top off pump reservoir.
14. Run engine, cycle steering wheel right to left stops several times.
15. Check and adjust power steering pump fluid level.
16. Check for leaks.
PART NUMBER PART NAME CLASS
E3FZ-3D728-A Seal Kit P/S Gear Valve A
D3FZ-3E501-A Seal Kit P/S Gear Rack A
OTHER APPLICABLE ARTICLES: 83-12-4, 83-14-5S
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual.
OPERATION: SP3504D
TIME: 1.3 Hr. DLR. CODING: Basic Part No. 3D517 - Code: As applicable.