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Home >> Mercury >> 2008 >> Milan Base, 2.3 Z, Automatic >> Repair and Diagnosis >> External Pages >> Different car >> Section 1378 (Power Steering System) >> Removal And Installation >> Steering Gear - All Wheel Drive (AWD) >> Installation

Steering Gear - All Wheel Drive (AWD): Installation

WARNING: This page is about a different car, the 2009 Mercury Milan, 2009 Lincoln MKZ, and 2009 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: When installing the steering gear, it is important to have the steering gear in the centered position or unequal right-to-left turns may occur, causing tire contact with the body and/or clockspring damage. A new steering gear is centered and ready for installation.
NOTE: When repairing the power steering system, care should be taken to prevent the entry of foreign material or failure of the power steering components may result.
  1. From the LH side of the vehicle, install the steering gear.
  2. Install the 3 steering gear bolts.
    • Tighten to 107 Nm (79 lb-ft).
  3. Connect the steering gear-to-fluid cooler return hose and connect the clamp.
  4. Using a suitable jack, raise the rear of the front subframe.
  5. Install the 4 rear subframe bolts and 2 rear subframe nuts.
    • To install, tighten the bolts and nuts in 2 stages.
      • Stage 1: Tighten the nuts to 150 Nm (111 lb-ft).
      • Stage 2: Tighten the bolts to 103 Nm (76 lb-ft).
  6. Install the steering gear heat shield and the 2 bolts.
    • To install, tighten to 15 Nm (133 lb-in).
    7. NOTE: Always install new fasteners and gaskets. Clean flange faces prior to new gasket installation to make sure of correct sealing.
  7. Position the exhaust flexible pipe and install the 2 new catalytic converter-to-exhaust flexible pipe nuts.
    • Tighten to 40 Nm (30 lb-ft).
    8. Fig 1: Identifying Catalytic Converter-To-Exhaust Flexible Pipe Nuts
    GF0029481Courtesy of FORD MOTOR CO.
  8. Install the 2 outer tie-rod end nuts.
    • Tighten to 48 Nm (35 lb-ft).
    • Install 2 new cotter pins.
  9. If equipped, install the underbody splash shield and bolts.
    • Tighten to 7 Nm (62 lb-in).
    10. NOTE: RH side shown, LH side similar.
  10. Install the LH and RH splash shield and the 6 pin-type retainers (4 shown).
    11. Fig 2: Locating Splash Shield Pin-Type Retainers
    G04684103Courtesy of FORD MOTOR CO.
    NOTE: RH side shown, LH side similar.
  11. Install the RH and LH fender splash shield and the 4 screws from each side.
    12. Fig 3: Locating RH Fender Splash Shield Screws
    G04684102Courtesy of FORD MOTOR CO.
  12. Install the pressure line bracket-to-steering gear bolt.
    • Tighten to 15 Nm (133 lb-in).
    13. NOTE: New banjo bolts and new seals must be installed any time the power steering pressure line is disconnected from the power steering pump and/or the steering gear or a fluid leak may occur.
  13. Install the new pressure line-to-steering gear banjo bolt and seals.
    • Tighten to 55 Nm (41 lb-ft).
    14. NOTE: Battery mounting bracket removed for clarity.
  14. Connect the electrical connectors to the PCM.
    • Attach the wiring harness retainer to the PCM bracket.
    15. Fig 4: Identifying Electrical Connectors From Power Control Module (PCM)
    GF0030214Courtesy of FORD MOTOR CO.
  15. Install the battery tray and battery. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
    16. NOTE: The steering gear/dash seal must be fully seated in the steering gear valve tower groove before the retaining clips are fully engaged into the body. If the steering gear/dash seal is not seated to the steering gear valve tower groove and the clips are not fully engaged to the body, water and foreign material may enter the passenger compartment and damage the vehicle interior.
  16. Applying hand force to the center of the seal, install the steering gear/dash seal onto the steering gear valve tower until the seal is fully seated in the valve tower groove.
    17. Fig 5: Locating Valve Tower Groove
    GF0030219Courtesy of FORD MOTOR CO.
  17. Install the steering gear/dash seal until the retaining clips are fully engaged into the body.
    18. Fig 6: Locating Steering Column Shaft-To-Dash Seal
    GF0029479Courtesy of FORD MOTOR CO.
    NOTE: Do not allow the steering column to rotate while the steering column shaft is disconnected from the steering gear or damage to the clockspring may occur. If there is evidence that the steering column has rotated, the clockspring must be removed and recentered. For additional information, refer to SUPPLEMENTAL RESTRAINT SYSTEM article.
    NOTE: Make sure to correctly align the index marks when installing the steering gear to steering column shaft or unequal right-to-left turns may occur, causing tire contact with the body and/or clockspring damage.
  18. With the index marks correctly aligned, connect the steering column shaft to the steering gear and install the new bolt.
    • Tighten to 25 Nm (18 lb-ft).
    19. Fig 7: Locating Steering Column Shaft Index Mark And Bolt
    GF0028748Courtesy of FORD MOTOR CO.
  19. Install the lower steering column shaft joint cover and the 2 nuts.
  20. Fill the power steering system. For additional information, refer to STEERING SYSTEM - GENERAL INFORMATION article.
  21. Check and, if necessary, adjust the front toe. For additional information, refer to SUSPENSION SYSTEM - GENERAL INFORMATION article.
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