Steering Gear - 3.5L All Wheel Drive (AWD): Removal

WARNING: This page is about a different car, the 2010 Mercury Milan, 2010 Lincoln MKZ, and 2010 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: When repairing the power steering system, care should be taken to prevent the entry of foreign material or failure of the power steering components may result.

Using a suitable holding device, hold the steering wheel in the straight-ahead position.
NOTE: Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent).

Fig 1: Identifying Steering Wheel Holding Device
Courtesy of FORD MOTOR CO.
Remove the wheels and tires. For additional information, refer to REMOVAL .
Remove the 2 lower steering column shaft joint cover nuts and the cover.
Index-mark the steering column shaft-to-steering gear position for reference during installation.
NOTE: Make sure to correctly index-mark the steering gear-to-steering column shaft position or unequal right-toleft turns may occur, causing tire contact with the body and/or clockspring damage.

Fig 2: Locating Index-Mark
Courtesy of FORD MOTOR CO.
Remove the bolt and disconnect the steering column shaft from the steering gear.
- Discard the bolt.
NOTE: Do not allow the steering column to rotate while the steering column shaft is disconnected from the steering gear or damage to the clockspring may occur. If there is evidence that the steering column has rotated, the clockspring must be removed and recentered. For additional information, refer to REMOVAL .

Fig 3: Locating Steering Column Shaft & Bolt
Courtesy of FORD MOTOR CO.
Pulling upward, remove the steering gear/dash seal.
NOTE: Remove the steering gear/dash seal or damage to the seal may occur.
Remove the battery and battery tray. For additional information, refer to BATTERY AND BATTERY TRAY -- EXPLODED VIEW .
Disconnect the electrical connectors from the PCM.
- Detach the wiring harness retainer from the PCM bracket and position the harness aside.
NOTE: Battery mounting bracket removed for clarity.

Fig 4: Locating PCM Electrical Connectors
Courtesy of FORD MOTOR CO.
Remove the pressure line-to-steering gear banjo bolt.
- Discard the bolt and 2 seals.
Remove the pressure line bracket-to-steering gear bolt.
If equipped, remove the 7 screws and the underbody cover.

Fig 5: Locating Underbody Cover & Screws
Courtesy of FORD MOTOR CO.
Remove the 4 screws from each side and position the RH and LH fender splash shield aside.
NOTE: RH side shown in illustration, LH side similar.

Fig 6: Locating RH & LH Fender Splash Shield & Screws
Courtesy of FORD MOTOR CO.
Remove the 6 pin-type retainers (4 shown in illustration) from the LH and RH splash shield.

Fig 7: Locating Pin-Type Retainers LH & RH Splash Shield
Courtesy of FORD MOTOR CO.
Remove the 2 outer tie-rod end cotter pins and nuts.
- Discard the cotter pins.
Using the Ball Joint Separator, separate the outer tie-rod ends from the knuckle.
NOTE: Do not use a hammer to separate the outer tie-rod end from the wheel knuckle or damage to the wheel knuckle may result.

Fig 8: Identifying Ball Joint Separator
Courtesy of FORD MOTOR CO.
Remove and discard the 2 catalytic converter-to-exhaust flexible pipe nuts and separate the exhaust flexible pipe.
NOTE: Always install new fasteners and gaskets. Clean flange faces prior to new gasket installation to make sure of proper sealing.

Fig 9: Locating Catalytic Converter-To-Exhaust Flexible Pipe Nuts
Courtesy of FORD MOTOR CO.
Remove the 2 bolts and the steering gear heat shield.
Support the rear of the subframe with a suitable jack and remove the 4 rear subframe bolts and 2 rear subframe nuts.
Lower the rear of the front subframe 76.2 mm (3 in) with the support of the jack.
Remove the pressure line bracket-to-steering gear bolt.
Release the clamp and disconnect the steering gear-to-fluid cooler return hose.
Remove the 3 steering gear bolts.
Remove the steering gear from the LH side of the vehicle.