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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 372 (Power Steering) >> Disassembly And Assembly >> Gear - Power Steering >> Disassembly

Gear - Power Steering: Disassembly

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.
NOTE: The steering gear input shaft and seals cannot be repaired or replaced separately. Gear replacement may be necessary.
  1. Secure the steering gear in a vise with the indexing flat pointed down. Use protective caps on the vise jaws.
    Fig 1: Securing Steering Gear In Vise
    G01948439Courtesy of FORD MOTOR CO.
  2. Rotate the power steering gear input shaft and control (3D517) from stop to stop and then center the gear.
    Fig 2: Rotating Power Steering Gear Input Shaft
    G01948440Courtesy of FORD MOTOR CO.
  3. Remove the steering gear sector shaft housing cover bolts.
    Fig 3: Removing Steering Gear Sector Shaft Housing Cover Bolts
    G01948441Courtesy of FORD MOTOR CO.
  4. Tap on the lower end of the steering gear sector shaft (3575).
    Fig 4: Taping On Lower End Of Steering Gear Sector Shaft
    G01948442Courtesy of FORD MOTOR CO.
  5. Remove the steering gear sector shaft.
    Fig 5: Removing Steering Gear Sector Shaft
    G01948443Courtesy of FORD MOTOR CO.
  6. Remove the locking nut from the steering gear sector shaft adjustment screw.
    Fig 6: Removing Locking Nut From Steering Gear Sector Shaft Adjustment Screw
    G01948444Courtesy of FORD MOTOR CO.
  7. Remove the sector shaft housing cover.
    • Hold the steering gear sector shaft.
    • Turn the housing cover counterclockwise.
      Fig 7: Turning Housing Cover Counterclockwise
      G01948445Courtesy of FORD MOTOR CO.
  8. Remove the valve housing bolts and the identification tag.
    Fig 8: Removing Valve Housing Bolts
    G01948446Courtesy of FORD MOTOR CO.
  9. Remove the valve housing and piston assembly.
    Fig 9: Removing Valve Housing And Piston Assembly
    G01948447Courtesy of FORD MOTOR CO.
  10. Remove the discard the gasket.
    Fig 10: Removing Gasket
    G01948448Courtesy of FORD MOTOR CO.
  11. Remove the ball bearings.
    1. Remove the bolts.
    2. Remove the steering gear ball return guide clamp (3544).
    3. Remove the steering gear ball return guide (3523).
    4. Rotate the piston over a container to collect the 28 steering gear worm balls (3647).
      Fig 11: Removing Ball Bearings
      G01948449Courtesy of FORD MOTOR CO.
  12. Remove the input shaft valve and housing assembly from the piston.
    Fig 12: Removing Input Shaft Valve And Housing Assembly From Piston
    G01948450Courtesy of FORD MOTOR CO.
  13. Remove and discard the seal.
    Fig 13: Removing Seal
    G01948451Courtesy of FORD MOTOR CO.
  14. Install the valve housing in the Bench Mounted Holding Fixture and loosen the setscrew.
    Fig 14: Installing Valve Housing In Bench Mounted Holding Fixture
    G01948452Courtesy of FORD MOTOR CO.
  15. Use Adjuster and Locknut Wrench to remove the race nut.
    Fig 15: Removing Race Nut
    G01948453Courtesy of FORD MOTOR CO.
  16. Remove the power steering gear input shaft and control from the valve housing.
    Fig 16: Removing Power Steering Gear Input Shaft And Control From Valve Housing
    G01948454Courtesy of FORD MOTOR CO.
  17. Rotate the valve housing with the Bench Mounted Holding Fixture.
  18. Use the puller to remove the power steering gear input shaft seal (3D526) dust seal.
    Fig 17: Removing Power Steering Gear Input Shaft Seal
    G01948455Courtesy of FORD MOTOR CO.
  19. Remove the input shaft snap ring.
    Fig 18: Removing Input Shaft Snap Ring
    G01948456Courtesy of FORD MOTOR CO.
  20. Rotate the valve housing with the Bench Mounted Holding Fixture, and use the Input Shaft Bearing/Seal Tool to remove the bearing and power steering gear input shaft seal.
    Fig 19: Rotating Valve Housing With Bench Mounted Holding Fixture
    G01948457Courtesy of FORD MOTOR CO.
  21. Remove the valve housing from the Bench Mounted Holding Fixture.
  22. Install the steering gear housing (3548) in the Bench Mounted Holding Fixture and remove the steering gear sector shaft dust seal from the sector shaft seal bore.
    Fig 20: Removing Steering Gear Sector Shaft Dust Seal From Sector Shaft Seal Bore
    G01948458Courtesy of FORD MOTOR CO.
  23. Remove the spacer.
    1. Remove the snap ring.
    2. Remove the spacer.
      Fig 21: Removing Snap Ring
      G01948459Courtesy of FORD MOTOR CO.
    24. NOTE: The steering gear sector shaft bearing is not replaceable.
    Fig 22: Removing Sector Shaft Seal
    G01948460Courtesy of FORD MOTOR CO.
  24. Use the Puller to remove the sector shaft seal.
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