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Gear - 4x4: Installation

WARNING: This page is about a different car, the 2003 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
  1. Using the special tool, install new seals on the power steering return hose and power steering pressure hose.
    Fig 1: Installing Seals On Power Steering Return & Pressure Hose
    G01269286Courtesy of FORD MOTOR CO.
    2. NOTE: Make sure the steering gear input shaft is turned to the left until the stop is reached.
    NOTE: Handle the steering gear with caution to avoid damage to fluid transfer tubes and to avoid dimples in tie-rod boots.
  2. Turn the steering gear input shaft to the right until the stop is reached. Note the number of turns required.
    3. NOTE: Make sure the steering gear control valve housing is turned toward the front of the vehicle.
    Fig 2: Installing Steering Gear Into Right Opening Of Crossmember
    G01269287Courtesy of FORD MOTOR CO.
  3. Install the steering gear into the RH opening of the crossmember.
  4. Move the steering gear as far to the RH side of the vehicle as possible.
    Fig 3: Moving Steering Gear To Right Side Of Vehicle
    G01269288Courtesy of FORD MOTOR CO.
  5. Move the LH front wheel spindle tie-rod into the opening in the crossmember and move the steering gear into position.
    Fig 4: Moving Left Front Wheel Spindle Tie-Rod Into Opening In Crossmember
    G01269289Courtesy of FORD MOTOR CO.
  6. To place the steering gear in the straight ahead position, turn the steering gear input shaft to the left by half the number of turns recorded previously.
  7. Rotate the steering gear control valve housing toward the rear of the vehicle.
    Fig 5: Rotating Steering Gear Control Valve Housing Toward Rear Of Vehicle
    G01269290Courtesy of FORD MOTOR CO.
  8. Install the steering gear to crossmember insulator bushings as shown.
    • The large end of the metal sleeve must be positioned downward.
    • Check that the mounting surfaces on the crossmember are clean and free of foreign material.
      Fig 6: Installing Steering Gear To Crossmember Insulator Bushings
      G01269291Courtesy of FORD MOTOR CO.
  9. Install the steering gear to crossmember washers and stud bolts.
    • The dished side of the washer faces downward.
      Fig 7: Installing Steering Gear To Crossmember Washers & Stud Bolts
      G01269292Courtesy of FORD MOTOR CO.
    10. CAUTION: Hold the tops of the steering gear to crossmember stud bolts to avoid damaging the steering gear fluid transfer tubes.
    Fig 8: Installing Nuts
    G01269293Courtesy of FORD MOTOR CO.
  10. Install the nuts.
  11. Install the lines and tighten the nut.
    Fig 9: Installing Lines
    G01269294Courtesy of FORD MOTOR CO.
    12. CAUTION: Do not allow the intermediate shaft to rotate while it is disconnected from the steering gear or damage to the clockspring can result. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to CLOCKSPRING .
    Fig 10: Connecting Intermediate Shaft To Steering Gear Input Shaft
    G01269295Courtesy of FORD MOTOR CO.
  12. Connect the intermediate shaft to the steering gear input shaft. Install a new lower steering column pinch bolt.
  13. Install the power steering fluid cooler. For additional information, refer to Cooler-Fluid  in this section.
  14. Install the front stabilizer bar. For additional information, refer to STABILIZER BAR .
    • Orientate the front stabilizer bar as noted during removal.
  15. Install the LH tie-rod end on the front wheel spindle tie-rod.
    • Rotate the tie-rod end the number of turns recorded during removal.
      Fig 11: Installing Left Tie-Rod End On Front Wheel Spindle Tie-Rod
      G01269296Courtesy of FORD MOTOR CO.
  16. Position the tie-rod ends on the steering knuckles. Install the castellated nuts and new cotter pins.
    • Check that the brake dust shields are not bent and are not in contact with the outer tie-rod boot seals.
      Fig 12: Positioning Tie-Rod Ends On Steering Knuckles
      G01269297Courtesy of FORD MOTOR CO.
  17. Tighten the tie-rod end jam nut.
    Fig 13: Tightening Tie-Rod End Jam Nut
    G01269298Courtesy of FORD MOTOR CO.
  18. Position the air deflector, and install the retaining screws.
    Fig 14: Installing Air Deflector Retaining Screws
    G01269299Courtesy of FORD MOTOR CO.
  19. Install the front wheel and tire assemblies.
  20. Fill, purge and leak check the system. For additional information, refer to GENERAL INFORMATION .
  21. Check and, if necessary, adjust the wheel alignment.
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