Steering Gear: Disassembly

WARNING: This page is about a different car, the 2003 Ford Pickup, 2003 Ford F550 Super Duty, 2003 Ford F450 Super Duty, 2003 Ford Excursion, and 2003 Ford Cab & Chassis. 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.

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 With Indexing Flat Pointed Down
Courtesy of FORD MOTOR CO.
Rotate the power steering gear input shaft and control from stop to stop and then center the gear by rotating the shaft 1.5 turns from the stop.

Fig 2: Rotating Power Steering Gear Input Shaft
Courtesy of FORD MOTOR CO.
Remove the steering gear sector shaft housing cover bolts.

Fig 3: Removing Steering Gear Sector Shaft Housing Cover Bolts
Courtesy of FORD MOTOR CO.
Tap on the lower end of the steering gear sector shaft.

Fig 4: Taping On Lower End Of Steering Gear Sector Shaft
Courtesy of FORD MOTOR CO.

CAUTION: If there is evidence of damage or wear to the steering gear sector shaft, you must install a new steering gear assembly.

Fig 5: Removing Steering Gear Sector Shaft

Courtesy of FORD MOTOR CO.

Remove the steering gear sector shaft.
Remove the valve housing bolts and the identification tag.

Fig 6: Removing Valve Housing Bolts And Identification Tag
Courtesy of FORD MOTOR CO.
Remove the valve housing and piston assembly.

Fig 7: Removing Valve Housing And Piston Assembly
Courtesy of FORD MOTOR CO.
Remove and discard the gasket.

Fig 8: Removing And Discarding Gasket
Courtesy of FORD MOTOR CO.
Remove and discard the seal.

Fig 9: Removing And Discarding Seal
Courtesy of FORD MOTOR CO.
Install the valve housing in the special tool and loosen the setscrew.

Fig 10: Installing Valve Housing In Special Tool And Loosening Setscrew
Courtesy of FORD MOTOR CO.
Using the special tool, remove the race nut.

Fig 11: Removing Race Nut
Courtesy of FORD MOTOR CO.
Remove the power steering gear input shaft and control from the valve housing.

Fig 12: Removing Power Steering Gear Input Shaft And Control From Valve Housing
Courtesy of FORD MOTOR CO.
Rotate the valve housing with the holding fixture.
Use the pilot bearing remover to remove the power steering gear input shaft seal dust seal.

Fig 13: Removing Power Steering Gear Input Shaft Seal Dust Seal
Courtesy of FORD MOTOR CO.
Remove the input shaft snap ring.

Fig 14: Removing Input Shaft Snap Ring
Courtesy of FORD MOTOR CO.
Rotate the valve housing with the holding fixture, and using the special tool, remove the bearing and power steering gear input shaft seal.

Fig 15: Removing Bearing And Power Steering Gear Input Shaft Seal
Courtesy of FORD MOTOR CO.
Remove the valve housing from the holding fixture.
Install the steering gear housing in the holding fixture. Using a suitable puller, remove the steering gear sector shaft dust seal from the sector shaft seal bore.

Fig 16: Installing Steering Gear Housing In Holding Fixture
Courtesy of FORD MOTOR CO.
Remove the spacer.
1. Remove the snap ring.
2. Remove the spacer.
  
  Fig 17: Removing Snap Ring And Spacer
  Courtesy of FORD MOTOR CO.

NOTE: The steering gear sector shaft bearing is not replaceable.

Fig 18: Removing Sector Shaft Seal

Courtesy of FORD MOTOR CO.

Using the special tool, remove the sector shaft seal.