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Steering Gear: Assembly

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. Lubricate the sector shaft seal bore with grease.
    Fig 1: Identifying Lubricating Sector Shaft Seal Bore
    G02770023Courtesy of FORD MOTOR CO.
  2. Using the special tool, install the sector shaft seal.
    • Lubricate the sector shaft seal with grease.
    Fig 2: Installing Sector Shaft Seal
    G02770024Courtesy of FORD MOTOR CO.
  3. Install the spacer.
    Fig 3: Installing Spacer
    G02770025Courtesy of FORD MOTOR CO.
  4. Install the snap ring.
    Fig 4: Installing Snap Ring
    G02770026Courtesy of FORD MOTOR CO.
    5. NOTE: Place the steering gear sector shaft dust seal on the special tool so the raised lip is toward the tool.
    Fig 5: Installing Sector Shaft Dust Seal
    G02770027Courtesy of FORD MOTOR CO.
  5. Using the special tool, install the sector shaft dust seal.
    • Lubricate the steering gear sector shaft dust seal with grease.
  6. Remove the steering gear housing from the holding fixture.
  7. Position the input shaft bearing in the valve housing and use the special tool and a press to seat the bearing.
    Fig 6: Positioning Input Shaft Bearing In Valve Housing
    G02770028Courtesy of FORD MOTOR CO.
  8. Using the special tool and a press, seat the power steering gear input shaft seal.
    Fig 7: Installing Power Steering Gear Input Shaft Seal
    G02770029Courtesy of FORD MOTOR CO.
  9. Install the input shaft snap ring.
    Fig 8: Installing Input Shaft Snap Ring
    G02770030Courtesy of FORD MOTOR CO.
  10. Using the special tool, install the power steering gear input shaft seal dust seal.
    Fig 9: Installing Power Steering Gear Input Shaft Seal Dust Seal
    G02770031Courtesy of FORD MOTOR CO.
  11. Mount the valve housing in the special tool.
    Fig 10: Mounting Valve Housing
    G02770032Courtesy of FORD MOTOR CO.
  12. Install the power steering gear input shaft and control into the valve housing.
    Fig 11: Installing Power Steering Gear Input Shaft And Control Into Valve Housing
    G02770033Courtesy of FORD MOTOR CO.
  13. Position the power steering gear race nut into the valve housing.
    Fig 12: Positioning Power Steering Gear Race Nut Into Valve Housing
    G02770034Courtesy of FORD MOTOR CO.
  14. Using the special tool, tighten the race nut.
    Fig 13: Tightening Race Nut
    G02770035Courtesy of FORD MOTOR CO.
  15. Install the setscrew.
    Fig 14: Installing Setscrew
    G02770036Courtesy of FORD MOTOR CO.
  16. Remove the valve housing from the holding fixture.
    Fig 15: Removing Valve Housing From Holding Fixture
    G02770037Courtesy of FORD MOTOR CO.
  17. Install a new gasket.
    Fig 16: Installing New Gasket
    G02770038Courtesy of FORD MOTOR CO.
  18. Lubricate the seal with grease and install a new teflon seal and rubber O-ring seal on the piston.
    Fig 17: Installing A New Teflon Seal And Rubber O-Ring Seal On Piston
    G02770039Courtesy of FORD MOTOR CO.
    19. NOTE: Make sure to align the oil passages in the steering gear housing.
    Fig 18: Installing Piston Assembly Into Steering Gear Housing
    G02770040Courtesy of FORD MOTOR CO.
  19. Install the piston assembly into the steering gear housing.
  20. Rotate the teeth so they are on the same plane as the steering gear sector shaft.
    Fig 19: Rotating Teeth For Same Plane As Steering Gear Sector Shaft
    G02770041Courtesy of FORD MOTOR CO.
  21. Loosely install the valve housing bolts and the identification tag, if so equipped.
    Fig 20: Installing Valve Housing Bolts And Identification Tag
    G02770042Courtesy of FORD MOTOR CO.
  22. Lubricate the O-ring on the sector shaft housing cover with grease.
    Fig 21: Lubricating O-Ring On Sector Shaft Housing Cover With Grease
    G02770043Courtesy of FORD MOTOR CO.
    23. NOTE: Loosely install the sector shaft housing bolts.
    Fig 22: Installing Sector Shaft And Housing Assembly
    G02770044Courtesy of FORD MOTOR CO.
  23. Install the sector shaft and housing assembly.
  24. Tighten the bolts.
    Fig 23: Tightening Bolts
    G02770045Courtesy of FORD MOTOR CO.
  25. Tighten the bolts.
    Fig 24: Tightening Bolts
    G02770046Courtesy of FORD MOTOR CO.
  26. Adjust the steering gear meshload. Refer to STEERING SYSTEM-GENERAL INFORMATION .
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