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Gear - Power Steering: Assembly

WARNING: This page is about a different car, the 2002 Ford RV Cutaway, 2002 Ford Econoline, 2002 Ford E550 Super Duty, 2002 Ford E450 Super Duty, and 2002 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
  1. Lubricate the sector shaft seal bore.
    • Use Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-MIC93-B and ESR-M1C159-A.
    Fig 1: Lubricating Sector Shaft Seal Bore
    G01948461Courtesy of FORD MOTOR CO.
  2. Use the Sector Shaft Seal Replacer to install the sector shaft seal.
    • Lubricate the sector shaft seal, using Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A.
    Fig 2: Installing Sector Shaft Seal
    G01948462Courtesy of FORD MOTOR CO.
  3. Install the spacer.
    Fig 3: Installing Spacer
    G01948463Courtesy of FORD MOTOR CO.
  4. Install the snap ring.
    Fig 4: Installing Snap Ring
    G01948464Courtesy of FORD MOTOR CO.
    5. NOTE: Place the steering gear sector shaft dust seal on the Sector Shaft Seal Replacer so the raised lip is toward the tool.
    Fig 5: Installing Steering Gear Sector Shaft Dust Seal
    G01948465Courtesy of FORD MOTOR CO.
  5. Use the Sector Shaft Seal Replacer to install the sector shaft dust seal.
    • Lubricate the steering gear sector shaft dust seal; use Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR- M1C159-A.
  6. Remove the steering gear housing from the Bench Mounted Holding Fixture.
  7. Position the input shaft bearing in the valve housing and use the Input Shaft Bearing/Seal Tool Set and a press to seat the bearing.
    Fig 6: Positioning Input Shaft Bearing In Valve Housing
    G01948466Courtesy of FORD MOTOR CO.
  8. Use the Input Shaft Bearing/Seal Tool and a press to seat the power steering gear input shaft seal.
    Fig 7: Installing Power Steering Gear Input Shaft Seal
    G01948467Courtesy of FORD MOTOR CO.
  9. Install the input shaft snap ring.
    Fig 8: Installing Input Shaft Snap Ring
    G01948468Courtesy of FORD MOTOR CO.
  10. Use the Input Shaft Bearing/Seal Tool to install the power steering gear input shaft seal dust seal.
    Fig 9: Installing Power Steering Gear Input Shaft Seal Dust Seal
    G01948469Courtesy of FORD MOTOR CO.
  11. Mount the valve housing in the Bench Mounted Holding Fixture.
    Fig 10: Mounting Valve Housing In Bench Mounted Holding Fixture
    G01948470Courtesy 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
    G01948471Courtesy of FORD MOTOR CO.
  13. Position the power steering gear race nut into the valve housing.
    Fig 12: Positioning Power Steering Gear Race Nut
    G01948472Courtesy of FORD MOTOR CO.
  14. Use the Adjuster and Locknut Wrench to tighten the race nut.
    Fig 13: Tightening Race Nut
    G01948473Courtesy of FORD MOTOR CO.
  15. Install the setscrew.
    Fig 14: Installing Setscrew
    G01948474Courtesy of FORD MOTOR CO.
  16. Remove the valve housing from the Bench Mounted Holding Fixture and position the piston on the worm gear.
    Fig 15: Removing Valve Housing From Bench Mounted Holding Fixture
    G01948475Courtesy of FORD MOTOR CO.
    17. WARNING: Hold the ball return guides until the cap or clip is reinstalled. Failure to hold the guides will result in a trapped ball or balls, which can cause a vehicle accident. If the ball guides become unseated at any time, remove all the balls and repeat the procedure.
    Fig 16: Installing Steering Gear Ball Return Guide On Piston
    G01948476Courtesy of FORD MOTOR CO.
  17. Install the steering gear ball return guide on the piston.
    18. WARNING: The correct number of balls are required for proper gear operation. Count the balls and insert each carefully.
    WARNING: To make sure the balls are properly installed, rotate the steering gear input worm gear and rack from one end of travel to the other without allowing the poppet adjuster to contact the valve housing or moving the valve housing pilot face more than 69.1 mm (2-3/4 inches) from the input end of the rack piston. If the steering gear input worm gear and rack cannot be rotated, reinstall the balls. If a steering gear is installed with a steering gear input worm gear and rack that cannot rotate, the steering gear will not function correctly and steering and gear failure can result.
    Fig 17: Checking Steering Gear Ball Return Guide
    G01948477Courtesy of FORD MOTOR CO.
  18. Rotate the piston while holding the steering gear ball return guide and install the 28 ball bearings into the opening in the ball guide.
  19. Install the steering gear ball return guide clamp.
    1. Position the steering gear ball return guide clamp.
    2. Install the bolts.
    Fig 18: Installing Steering Gear Ball Return Guide Clamp
    G01948478Courtesy of FORD MOTOR CO.
  20. Install a new gasket.
    Fig 19: Installing Gasket
    G01948479Courtesy of FORD MOTOR CO.
  21. Lubricate and install the seal on the piston.
    • Use Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A.
    Fig 20: Installing Seal On Piston
    G01948480Courtesy of FORD MOTOR CO.
    22. NOTE: Make sure to align the oil passages in the steering gear housing.
    Fig 21: Installing Piston Assembly Into Steering Gear Housing
    G01948481Courtesy of FORD MOTOR CO.
  22. Install the piston assembly into the steering gear housing.
  23. Rotate the teeth so they are on the same plane as the steering gear sector shaft.
    Fig 22: Identifying Steering Gear Sector Shaft
    G01948482Courtesy of FORD MOTOR CO.
  24. Loosely install the valve housing bolts and the identification tag, if so equipped.
    Fig 23: Installing Valve Housing Bolts
    G01948483Courtesy of FORD MOTOR CO.
  25. Lubricate the O-ring on the sector shaft housing cover.
    • Use Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A.
    Fig 24: Lubricating O-Ring On Sector Shaft Housing Cover
    G01948484Courtesy of FORD MOTOR CO.
  26. Rotate the housing clockwise and install the sector shaft into the sector shaft housing.
    Fig 25: Installing Sector Shaft Into Sector Shaft Housing
    G01948485Courtesy of FORD MOTOR CO.
    27. NOTE: The sector shaft lock nut will be tightened during the steering gear meshload adjustment.
    Fig 26: Installing Sector Shaft Lock Nut
    G01948486Courtesy of FORD MOTOR CO.
  27. Install the sector shaft lock nut.
    28. NOTE: Loosely install the sector shaft housing bolts.
    Fig 27: Installing Sector Shaft And Housing Assembly
    G01948487Courtesy of FORD MOTOR CO.
  28. Install the sector shaft and housing assembly.
  29. Tighten the bolts.
    Fig 28: Tightening Bolts
    G01948488Courtesy of FORD MOTOR CO.
  30. Tighten the bolts.
    Fig 29: Tightening Bolts
    G01948489Courtesy of FORD MOTOR CO.
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