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Removal and Installation

WARNING: This page is about a different car, the 2004 Ford RV Cutaway, 2004 Ford Econoline, 2004 Ford E450 Super Duty, and 2004 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: New O-ring seals must be installed any time the lines are disconnected from the steering gear.

    ALL VEHICLES 

  1. Place the front wheels in the straight-ahead position and the ignition switch in the OFF position.
    2. CAUTION: Do not allow the steering column shaft to rotate while the intermediate shaft is disconnected or damage to the clockspring can result. If there is evidence that the shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to AIR BAG RESTRAINT SYSTEMS .
    Fig 1: Removing/Installing Intermediate Shaft Bolt
    G02761430Courtesy of FORD MOTOR CO.
  2. Remove the bolt and detach the intermediate shaft from the gear.
  3. Disconnect the lines.
    • Discard the O-ring seals.
    Fig 2: Removing/Installing Lines
    G02761431Courtesy of FORD MOTOR CO.
  4. With vehicle in NEUTRAL, place on a hoist. For additional information, refer to JACKING & LIFTING .
  5. Remove and discard the cotter pin and nut.
    Fig 3: Removing/Installing Cotter Pin And Nut
    G02761432Courtesy of FORD MOTOR CO.
  6. Using the special tool, separate the drag link.
    Fig 4: Separating Drag Link
    G02761433Courtesy of FORD MOTOR CO.

    7. VEHICLES BUILT TO 1/17/04 

  7. Remove the bolts and the steering gear.
    Fig 5: Identifying Loosening Torque Of Steering Gear Bolts (Vehicles Built To 1/17/04)
    G02761434Courtesy of FORD MOTOR CO.

    8. VEHICLES BUILT FROM 1/17/04 

  8. Remove the bolts and the steering gear.
    Fig 6: Identifying Loosening Torque Of Steering Gear Bolts (Vehicles Built From 1/17/04)
    G02761435Courtesy of FORD MOTOR CO.

    9. ALL VEHICLES 

  9. Secure the steering gear in a vise and remove the nut and lock washer.
    Fig 7: Identifying Loosening Torque Of Steering Gear Nut
    G02761436Courtesy of FORD MOTOR CO.
  10. Using the special tool, remove the steering gear sector shaft arm.
    Fig 8: Removing Steering Gear Sector Shaft Arm
    G02761437Courtesy of FORD MOTOR CO.
  11. To install, reverse the removal procedure.
    • Install a new high pressure hose O-ring seal (N803256-S) and a new return hose O-ring seal (N802357-S).
  12. Fill and leak check the system. For additional information, refer to STEERING SYSTEM-GENERAL INFORMATION .
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