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Gear - Torsion Bar Suspension: Installation

WARNING: This page is about a different car, the 2004 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
    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 the tie -rod boots.
  1. Turn the steering gear input shaft to the right until the stop is reached. Note the number of turns required.
    2. NOTE: Make sure the steering gear control valve housing is turned toward the front of the vehicle.
    Fig 1: Installing Steering Gear
    G03273244Courtesy of FORD MOTOR CO.
  2. Install the steering gear into the RH opening of the crossmember.
    3. CAUTION: Take care not to scuff or tear the inner tie -rod boots.
    Fig 2: Moving Steering Gear To Right Side Of Vehicle
    G03273245Courtesy of FORD MOTOR CO.
  3. Move the steering gear as far to the RH side of the vehicle as possible.
  4. Move the LH front wheel spindle tie-rod into the opening in the crossmember and move the steering gear into position.
    Fig 3: Moving LH Front Wheel Spindle Tie-Rod
    G03273246Courtesy of FORD MOTOR CO.
  5. 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 previously recorded.
  6. Rotate the steering gear control valve housing toward the rear of the vehicle.
    Fig 4: Rotating Steering Gear Control Valve Housing
    G03273247Courtesy of FORD MOTOR CO.
  7. Install the steering gear crossmember washers and stud bolts.
    • The dished side of the washer faces downward.
      Fig 5: Installing Steering Gear Crossmember Washers And Stud Bolts
      G03273248Courtesy of FORD MOTOR CO.
    8. CAUTION: Hold the tops of the steering gear to crossmember stud bolts to avoid damaging the steering gear fluid transfer tubes.
    Fig 6: Installing Nuts
    G03273249Courtesy of FORD MOTOR CO.
  8. Install the nuts.
  9. Install the lines and tighten the nut.
    Fig 7: Installing Lines And Tightening Nut
    G03273250Courtesy of FORD MOTOR CO.
    10. 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 re-centered. For additional information, refer to AIR BAG RESTRAINT SYSTEMS .
    Fig 8: Installing Lower Steering Column Pinch Bolt
    G03273251Courtesy of FORD MOTOR CO.
  10. Connect the intermediate shaft to the steering gear input shaft. Install a new lower steering column pinch bolt.
  11. Install the cooler, hose and clamp.
    Fig 9: Installing Cooler, Hose And Clamp
    G03273252Courtesy of FORD MOTOR CO.
  12. Connect and install the clamp.
    Fig 10: Connecting & Installing Clamp
    G03273253Courtesy of FORD MOTOR CO.
  13. Install the nuts.
    Fig 11: Installing Nuts
    G03273254Courtesy of FORD MOTOR CO.
    14. NOTE: In the event that the self-tapping bolts cannot be installed in the frame, there is a kit available with flag nuts. Consult your parts department for additional information.
  14. Install the front stabilizer bar.
    • Install the stabilizer bar insulators.
    • Install the front stabilizer bar brackets.
    • Install the bolts.
      Fig 12: Installing Front Stabilizer Bar
      G03273255Courtesy of FORD MOTOR CO.
  15. Install the front stabilizer bar links and the front stabilizer bar bolts.
    Fig 13: Installing Front Stabilizer Bar Links
    G03273256Courtesy of FORD MOTOR CO.
  16. Install the front stabilizer bar link nuts.
    Fig 14: Installing Front Stabilizer Bar Link Nuts
    G03273257Courtesy of FORD MOTOR CO.
  17. Install the tie-rod ends on the front wheel spindle tie-rods.
    • Rotate the tie-rod ends the number of turns recorded during removal.
      Fig 15: Installing Tie-Rod Ends On Front Wheel Spindle Tie-Rods
      G03273258Courtesy of FORD MOTOR CO.
  18. 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 boots.
      Fig 16: Installing Castellated Nuts And Cotter Pins
      G03273259Courtesy of FORD MOTOR CO.
  19. Tighten the tie -rod end jam nuts.
    Fig 17: Tightening Tie-Rod End Jam Nuts
    G03273260Courtesy of FORD MOTOR CO.
  20. Install the front wheel and tire assemblies. For additional information, refer to WHEELS & TIRES .
  21. Fill and leak check the system. For additional information, refer to STEERING SYSTEM-GENERAL INFORMATION .
  22. Check and, if necessary, adjust the wheel alignment. For additional information, refer to SUSPENSION SYSTEM-GENERAL INFORMATION .
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