Removal and Installation
Special Service Tool(s) Required
Description Tool Number
T94T-6000-AH Exhaust Connector Holder Tool
T57L-500-B Bench Mounted Holding Fixture
Removal
1. Disconnect negative battery cable.
2. Position steering wheel one-half turn to right and lock wheel.
3. Partially raise vehicle.
4. Remove front wheel and tire assemblies.
5. Remove LH upper stabilizer bar link retaining nut and position link out of the way.
6. Loosen LH tie-rod jam nut.
Remove cotter pin and tie-rod retaining nut at steering knuckle.
Using tie-rod end separator or equivalent, remove tie-rod from steering knuckle and from steering gear.
7. Position steering column boot out of the way.
Remove pinch bolt retaining steering column intermediate shaft coupling to power steering short rack and separate.
8. Remove RH upper stabilizer bar link retaining nut and position out of the way.
9. Loosen RH tie-rod retaining nut at steering knuckle.
Using tie-rod end separator or equivalent, remove tie-rod from steering knuckle and from steering gear.
10. Raise vehicle.
11. Remove two steering gear retaining nuts at front subframe.
12. Install Exhaust Connector Holder Tool T94T-6000-AH to flex tube.
13. Remove retaining bolts and gasket where flex tube and converter Y-pipe connect.
Separate tube from pipe.
14. Position Rotunda Power Train Lift 014-00765 or equivalent under subframe and raise, using rear lifting points only.
15. Remove two rear subframe retaining bolts and lower subframe approximately 102 mm (4 inches).
16. Disconnect power steering auxiliary actuator and power steering pressure switch electrical connectors.
17. Disconnect two HO2S connectors and locators from power steering hose bracket and position aside.
18. Remove two heat shield pushpin retainers from power steering hose bracket and remove heat shield.
19. Remove two retaining bolts securing power steering hoses to rear of subframe and at power steering bracket.
20. Disconnect power steering hose locator from bracket.
Remove two retaining bolts from power steering hose bracket at steering gear and remove bracket.
21. Position drain pan under steering gear.
22. Remove power steering pressure and return hoses from fittings on power steering rack.
Place protective caps over both hoses and position out of the way.
23. Remove drain pan.
24. Rotate power steering rack to clear bolts from subframe and remove assembly through LH wheel well.
Position on bench and remove steering gear retaining bolts.
25. Mount steering gear assembly in Bench Mounted Holding Fixture T57L-500-B.
26. Remove four clamps retaining bellows to steering gear and tie-rods.
Remove bellows and power steering gear rack tube.
27. Position rack and pinion steering gear so several steering gear teeth are exposed.
Hold steering gear with adjustable wrench on end teeth only, while loosening inner tie-rods.
Remove tie-rods from steering rack.
28. Remove steering rack from bench-mounted holding fixture.
Power Rack and Pinion Steering Gear Components
Variable Assist Power Steering, System Components
Installation
1. Mount new steering gear assembly in Bench Mounted Holding Fixture T57L-500-B.
2. Position rack and pinion steering gear with teeth exposed.
Hold steering gear with adjustable wrench on end teeth only, while tightening inner tie-rods.
Tighten to 90-110 Nm (66-81 ft-lbs.).
3. Apply Steering Gear Grease C3AZ-19518-A meeting Ford specification ESB-M1C119-A to groove in connecting rods where tie-rod bellows clamp to front wheel spindle tie-rod and uniformly apply to inner diameter of bellows.
Install bellows and gear rack tube onto short rack.
4. Install new inner and outer bellows clamps.
5. Remove steering gear from Bench Mounted Holding Fixture and place on bench.
6. Install power steering short rack through LH wheel well and position on top of subframe.
7. Remove protective caps and old Teflon� O-rings from pressure and return hoses.
Using Seal Installer D90P-3517-A or equivalent, install new Teflon� O-rings on pressure and return hoses.
8. Position and install power steering pressure hose to fittings on power steering short rack.
Tighten to 33-41 Nm (24-30 ft-lbs.).
9. Position steering rack, install retaining bolts through subframe, and install nuts finger-tight.
Do not tighten at this time.
10. Connect electrical connectors to power steering auxiliary actuator and power steering pressure switch.
11. Install power steering hose bracket and retaining bolts at top of steering gear.
Tighten to 9-12 Nm (80-106 in-lbs).
Position heat shield at power steering hose bracket and install pushpin retainers.
12. Install two retaining bolts securing power steering hoses to rear or subframe and at power steering bracket.
Connect hose locator at power steering bracket.
Tighten to 9-12 Nm (80-106 in-lbs).
13. Connect two HO2S connectors and locators at power steering hose bracket.
14. Raise powertrain lift until rear subframe contacts body and install retaining bolts.
Tighten to 135-195 Nm (100-144 ft-lbs.).
Lower and remove powertrain lift from vehicle.
15. Tighten power steering short rack-to-subframe nuts.
Tighten to 97-132 Nm (72-97 ft-lbs.).
16. Install new gasket, bolts, and nuts at converter Y-pipe and flex tube.
Tighten to 34-46 Nm (26-34 ft-lbs.).
17. Remove flex tube holder.
18. Partially lower vehicle.
19. Install steering column intermediate shaft coupling to power steering short rack and install pinch bolt.
Tighten to 41-51 Nm (30-38 ft-lbs.).
Position steering column boot over steering rack.
20. Install LH jam nut and outer tie-rod to inner tie-rod.
Install tie-rod to steering knuckle and install retaining nut.
Tighten to 47-63 Nm (35-46 ft-lbs.).
Install new cotter pin.
21. Install LH stabilizer bar link and retaining nut.
Tighten to 76.5-103.5 Nm (56-76 ft-lbs.).
22. Install RH jam nut and outer tie-rod to inner tie-rod.
Install tie-rod to steering knuckle and install retaining nut.
Tighten to 47-63 Nm (35-46 ft-lbs.).
Install new cotter pin.
23. Install RH stabilizer bar link and retaining nut.
Tighten to 76.5-103.5 Nm (56-76 ft-lbs.).
24. Install tire and wheel assemblies.
Tighten to 115-142 Nm (85-105 ft-lbs.).
25. Lower vehicle.
26. Fill and purge system.
27. Check operation.
28. Adjust only toe for alignment.