Steering Gear - 3.5L Front Wheel Drive (FWD): Removal

WARNING: This page is about a different car, the 2011 Mercury Milan, 2011 Lincoln MKZ, and 2011 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.

NOTE: Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent).

Fig 1: Holding Steering Wheel Using Holding Device

Courtesy of FORD MOTOR CO.

Using a suitable holding device, hold the steering wheel in the straight-ahead position.
Remove the wheels and tires. For additional information, refer to WHEELS & TIRES article.
Remove the 2 lower steering column shaft joint cover nuts and the cover.

NOTE: Make sure to correctly index-mark the steering gear-to-steering column shaft position or unequal right-to-left turns may occur, causing tire contact with the body and/or clockspring damage.

Fig 2: Locating Steering Column Shaft-To-Steering Gear Position Index Mark

Courtesy of FORD MOTOR CO.

Index-mark the steering column shaft-to-steering gear position for reference during installation.

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 SUPPLEMENTAL RESTRAINT SYSTEM -- FUSION, MILAN & MKZ article.

Remove the bolt and disconnect the steering column shaft from the steering gear.
- Discard the bolt.
  
  Fig 3: Locating Index Mark, Steering Column Shaft And Mounting Bolt
  Courtesy of FORD MOTOR CO.

NOTE: Remove the steering gear/dash seal or damage to the seal may occur.

Pulling upward, remove the steering gear/dash seal.
If equipped, remove the 7 screws and the underbody cover.

Fig 4: Locating Underbody Cover With Mounting Screws
Courtesy of FORD MOTOR CO.

NOTE: RH side shown in the illustration, LH side similar.

Fig 5: Locating RH And LH Fender Splash Shield Mounting Screws

Courtesy of FORD MOTOR CO.

Remove the 4 screws from each side and position the RH and LH fender splash shield aside.
Remove the 6 pin-type retainers (4 shown in the illustration) from the LH and RH splash shield.

Fig 6: Locating RH And LH Fender Splash 6-Pin Type Retainers
Courtesy of FORD MOTOR CO.
Remove the 2 outer tie-rod end cotter pins and nuts.
- Discard the cotter pins.

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 7: Separating Outer Tie-Rod Ends From Knuckle Using Ball Joint Separator

Courtesy of FORD MOTOR CO.

Using the Ball Joint Separator, separate the outer tie-rod ends from the knuckle.

NOTE: Always install new fasteners and gaskets. Clean flange faces prior to new gasket installation to make sure of proper sealing.

Fig 8: Locating Catalytic Converter-To-Exhaust Flexible Pipe Nuts

Courtesy of FORD MOTOR CO.

Remove and discard the 2 catalytic converter-to-exhaust flexible pipe nuts and separate the exhaust flexible pipe.
Remove the 2 bolts and the steering gear heat shield.
Remove the pressure line bracket-to-steering gear bolt.
Remove the pressure line-to-steering gear banjo bolt.
- Discard the bolt and 2 seals.
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.
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.