Werkstatthandbuch Book 1 · Seiten 201–300

13-40-2 NIon-Integrol Power Steering System-Ford 13-40-2 ,rLuID LINES TYPICAL PCUTNG TO HYOPOBOOST ORAKE BOOSTER STEER ING LINKAGE CONTROL VALVE

13-40-3 Non-Integral Power Steering System-Ford 13-404 SPRING SEAT ADAPTER PLATE WASHER SPACER VALVE SEAL BUSHING SPRING CAP WASHER VALVE SPRING 0-RING

13-40-4 Non-Integral Power Steering System-Ford 13-40-4 REMOVAL AND INSTALLATION CONTROL VALVE Removal 1. Raise the vehicle and remove the worm-screw hose clamp that secures the fluid lines to the outside of the control valve body. 2. Disconnect the four fluid line fittings at the control valve and drain the fluid from the lines. Turn the front wheels to the left and right several times to force all of the fluid from the system. 3. Loosen the clamping nut and bolt at the end of the control valve sleeve. 4. Remove the roll pin from the steering arm-to-center link through the slot in the control valve sleeve. 5. Remove the cotter pin and the control valve ball stud nut. Remove the ball stud from the sector shaft arm Pitman Arm. When removing

13-40-5 Non-Integral Power Steering System-Ford 13-40-5 8. Lower the vehicle and fill the fluid reservoir with 3. Remove the cotter pin and castellated nut that fluid per Start Up Procedure given in Part 13-01. secures the power cylinder stud to the centerlink. 9. With the engine running at idle speed, check the 4. Disconnect the power cylinder stud from the position of the steering wheel when the front wheels centerlink. It is necessary to use the steering arm are in the straight-ahead position. Do not make remover tool, No. T64P-3590-F Fig. 6. Use of any any adlustments until the toe is checked. other tool will result in damage to the power 10. Keep the engine running, check the toe. If either

13-40-6 Non-Integral Power Steering System-Ford 13-40-6 CONTROL VALVE TO POWER STEERING 4. Raise the vehicle and connect the pressure and CYLINDER HOSE return lines to the control valve, finger tight. 5. Install the worm-screw clamp on the lines andRemoval torque to 36-60 in-lb1 now torque the tube nuts in 1. Raise the vehicle and disconnect the control valve- Step 4; the return hose nut 5/8" hex to 1 6-25 to-power cylinder hoses from the power cylinder ft-ib, and the pressure hose nut 1/2" hex to 15.19 and allow the fluid to drain.

13-40-7 Non-Integral Power Steering Systeni--Ford - 13-40-7 18/16 0.0. xO STEEL ELECTRICAL CONDUIT OR FA8RICATCNTnt SEMIL AR FIG. 9 Installing Power Cylinder Seals DISASSEMBLY AND ASSEMBLY CONTROL VALVE Disassembly 1. Remove the control valve as described in this Part and wipe all loose dirt and fluid from the outside. 2. Remove the control valve spring cap and spring cap gasket from the valve housing Fig. 2. For disassembly, use a soft-lawed vise and clamp the valve around the sleev. flange to prevent damage to the housing, spool, or sleeve. 3. Remove the centering spring adjusting nut from the end of the control v

13-40-8 Non-Integral Power Steering System-Ford 13-40-8 Insert the ball stud through the openings in the DUST SHIELD valve sleeve and the ball stud socket Fig. 14. Pull the socket out as far as possible and hold it on the socket at the ball stud opening Fig. 10. Insert the remaining seat, round side toward stud. Install the bumper and the bumper spring. Assemble the travel

13-40-9 Non-Integral Power Steering System-Ford 13-40-9 Torque nut to 90-100 in-Ib, then loosen the nut with 90-100 EN - LBS THEN respect to the spool bolt 1/4 turn Fig. 16. The ball TIGHTEN NUT SNUG stud socket will turn first. The 1/4 turn applies after LOOSEN S TURN ON THREADS OF BOLT the stud has hit the sleeve window and the spool bolt has turned to its stop. VALVE HOUSING ADJUSTING NUT CENTERING SPRING

13-40-10 Non-Integral Power Steering System-Ford 13-40-10 SPECIFICATIONS POWER ASSIST STEERING GEAR SPECIFICATIONS POWER ASSIST STEERING GEAR TORQUE LIMITS FT-U DescrIption Granada/Monarch, Versailles Description Torque Limit Model SMA-Y Sector Sheft Cover Bolts 17-25 Gear Ratio 16:1 Mesh Load Adjusting Screw Lock Nut 32-40 Ball Return Guide Clamp Screw 18-42 In-LW Tur

13-41-1 Integral Power Steering Gear - Ford 13-41-1 PART Integral Power Steering Gear- Ford 13-41 Applies To Ford/Mercury, LTD II, Cougar, Thunderbird, Lincoln Continental, and Continental Mark V SUBJECT PAGE SUBJECT PAGE ADJUSTMENTS DISASSEMBLY AND ASSEMBLY Cont’d. Mesh Load 41-2 Valve Housing 41-5 Rotary Valve Centering Check 41-2 Worm and Valve Sleeve 41-6 DESCRIPTION OPERATION

13-41-2 Integral Power Steering Gear - Ford 13-41-2 steering efforts, increased valve displacement will give extremely objectionable. A replacement valve will the driver proportionately higher assisting pressure. The also exhibit slight noise, and is not always a cure driver will have a smooth hydraulic assist at all times. for the complaint. Any metal-to-metal contacts at When the driver stops applying steering effort, the the flexible steering shaft coupling due to column valve is forced back to a centered position by the misalignment will transmit valve hissing noise into torsion bar. When this occurs, pressure is equalized on the passenger compartment. both sides of the piston. The steering geometry will tend

13-41-3 Integral Power Steering Gear - Ford 13-41-3 REMOVAL AND INSTALLATION STEERING GEAR Removal Installation 1. Tag the pressure and return lines for future 1. Slide the flex coupling into place on the steering identification. shaft assembly. Turn the steering wheel so the 2. Disconnect the pressure and return lines from the spokes are in the normal position. steering gear. Plug the lines and ports in the gear 2. Center the steering gear input shaft. to prevent entry of dirt. 3. Slide the steering gear input shaft into the flex 3. Remove the bolts that secure the flexible couplin

13-41-4 Integral Power Steering Gear - Ford 13-41-4 REMOVING WORM BEANING RACE NUT TOOL TGGP.3553-C FIRST GROOVE OP WORM SHOULD BE IN ALIGNMENT WITH THIS HOLE 01854-lB TOOL T6SP-3 553-B FIG. 6 Assembling Piston on Worm Shaft TB7L-500-B 01699-

13-41-5 Integral Power Steering Gear - Ford 13-41-5 identification tog and sector shaft cover bolts. 3. Remove the upper seal from the housing. Torque the bolts to specification. 4. Lubricate both new sector shaft seals with clean 6. Using an in-lb torque wrench, adjust the gear input lubriplate or equivalent. shaft meshload to specification. 5. Apply lubniplate or equivalent to the sector shaft seal bore in the housing. STEERING GEAR HOUSING 6. Place the dust seal on tool T77L-3576-A so the Disassembly and Assembly

13-41-6 Integral Power Steering Gear - Ford 13-41-6 VALVE HOUSING 3A587 -387109-S P,ess Ram Jj DUST SEAL 3DB27 01549-iC FIG. 9 Valve Housing Disassembled 01363-IA FIG. 11 Installing Valve Housing Bearing

13-41-7 Integral Power Steering Gear - Ford 13-41-7 PUSH ON BACK SIDE OF VALVE SLEEVE RINGS. INSERT KNIFE LADE CAREFULLY AND CUT ING WITHOUT SCRATCHING ALVE SLEEVE. MANDREL TOQL-T7SL-3517-A FIG. 13 Removing Valve Sleeve Rings FIG. 15 Mandrel Installed on Sleeve PUSHER TOOL T7SL-35,7-A2 FIG. 14 Worm and Sleeve With Ring Removed groove of the valve sleeve. Repeat

13-41-8 Integral Power Steering Gear - Ford 13-41-B SIZING TUBE TOOL T75L3517-A4N 6213DIA FIG. 17 Adding Spacer to Install Next Ring FIG. 19 Sizing Rings-Step 2 TOOL- T75L-351 7-A - TOOL-TJEL-3517.A2

13-41-9 Integral Power Steering Gear - Ford 13-41-9 FORD INTEGRAL POWER STEERING GEAR SPECIFICATIONS FORD INTEGRAL POWER STEERING GEAR TORQUE LIMITS FT-La Description Description Torque Type Recirc Ball Torsion Bar Sector Shaf I Cover Bolts 55J0 Mesh Load Adjosting Screw Lock Nut 35-45 Ratio 17:1 Ball Retorn Guide Clamp Screw 42-70 In-Lb Turns of Steering

13-42-1 Integral Power Steering Gear-Saginaw 13-42-1 Integral Power 1342 - Steering Gear Saginaw Applieslo LTDII,Cougar,XRJ,Thunderbird,Ranchero5.O/5.8 L302/351 WCI 0 Except Police and Taxi SUBJECT PAGE SUBJECT PAGE ADJUSTMENTS 42-2 DISASSEMBLY AND ASSEMBLY Contd. Stub Shaft and DESCRIPTION 42-1 Rotary Valve Assembly 4210 DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION 42-6

13-42-2 Integral Power Steering Gear-Saginaw 13-42-2 ADJUSTMENTS of the drag torque i.e., drag torque reading 3 in-Ibs, total torque reading with adjuster plug Only the over-center mesh load may be adjusted tightened 6-7 in-Ibs. with the steering gear in the vehicle. Other adjustments 6. Tighten the adjuster plug lock nut securely Fig. 9. require removal of the gear. NOTtt Preload torque tends to thop offTHRUST BEARING ADJUSTMENT-GEAR

13-42-3 Integral Power Steering Gear-Saginaw 13-42-3 inward using a 7/32-inch Allen wrench, until the reading is 6 in-lb greater than the reading taken in Step 4. Retighten the lock nut while holding the screw in place. 6. Recheck the readings and replace ‘the Pitman arm and steering wheel hub. 7. Connect the fluid return line to the reservoir and fill the reservoir with C1AZ-19582-A, C, or -D or equivalent to specification. 0’ RING C2985-lA FIG. 4 Removing Adjuster Plug Lock Nut WGRM SH

13-42-4 Integral Power Steering Gear-Saginaw 13-42-4 S TURNING AT EVEN RATE 02989-lA 02992-lA FIG. 7. Marking Housing 3/16 Inch FIG. 10 Checking Rotational Torque Counterclockwise from Bottomed Position C2993-IA 02990-lA FIG. 11 L

13-42-5 Integral Pawer Steering Gear-Saginaw 13-42-5 c2S9G-IA FIG. 13 Aligning Stub Shaft Flat C2997-l A FIG. 15 Checking Over-Center Rotational Torque C 2996-lA FIG. 14 Aligning Pitman Shaft Block Tooth REMOVAL AND INSTALLATION STEERING GEAR Removal 1. Remove the catalytic coverter on V-8 engined 6. On vehicles with standard transmissions, remove vehicles so equipped. Refer

13-42-6 Integral Power Steering Gear-Saginaw 13-42-6 3. Slide the steering gear input shaft into the flex 7. Install the catalytic converter, if so equipped. coupling and into place on the frame side rail. 8. Disconnect the coil wire. Fill the pump reservoir with Install the attaching bolts and torque to Automatic Transmission Fluid CIAZ.19582.A, . specification. or -D or equivalent. Crank the engine with the starter and continue adding fluid until the 4. Be sure that the wheels are in the straight- ahead position. Then install the Pitman arm on the level remains constant. Turn the steering wheel

13-42-7 Integral Power Steering Gear-Saginaw 13-42-7 3812 NUT t COVER 3580 GASKET 358 ADJUSTER 0-RING SPOOL SECTOR SHAFT 3575 DAMPER SEAL FLEXIBLE PORT SEAT

13-42-8 Integral Power Steering Gear-Saginaw 13-42-8 01630-24 FIG. 20 Installing Valve and Worm Shaft in Housing with the center of the sector shaft roller bearing. Be sure the cover 0-ring is in place before pushing Remove the tool from the housing. the cover dawn on the housing. 11. Lubricate a new 0-ring with power steering fluid 14. Install the cover screws and lock washers. Torque and place it in the sector shaft cover. to 30 to 35 ft-lbs. 12. Thread the sector shaft cover on the adjusting screw

13-42-9 Integral Power Steering Gear-Saginaw 13-42-9 21. After obtaining proper mesh load, torque the sector 2. Remove the lower seal double lip, spacer washer shaft adjustment screw lock nut to 27 to 37 ft-lbs. and upper seal single lip using Tools T58L-101-A and T59L-100-B Fig. 24. STEERING GEAR HOUSING 3. Check the housing bearing for wear and damage Disassembly and Assembly and remove, if necessary. Working from the lower end of the housing Fig. 25 press the bearing out1. Remove the snap ring Fig. 23 that secures the

13-42-10 Integral Power Steering Gear-Saginaw 13-42-10 7. To remove a damaged port seat, turn it two turns into the seat with a 5/16-18 inch U.S. thread 5116-lBxBOLT 2’ coarse tap. Coat the end of the tap with petrolatum to prevent chips from entering the passage. 8. Install a bolt and nut with a flat washer into the tapped hole Fig. 27. 9. Hold the bolt to keep it from turning and tighten NUT the nut to extract the seat. Discard the seat. 10. Remove the check valve and spring from the inlet port. WASHERF

13-42-11 Integral Power Steering Gear-Saginaw 13-42-11 4. Insert the drive pin into the hole and pull the assembly into the valve body, keeping the cap slot and body pin aligned. When the cap seats correctly in the valve body, the top surface of the cap should be at least 3/32 inch below the deep body notch. 5. Replace the cap-to-body 0-ring.

13-42-12 Integral Power Steering Gear-Saginaw 13-42-12 TOOL - TGSP-3O525-A / ADJUSTER WOOD BLOCK PLUGN 01636-lA FIG. 31 Removing or Installing Roller Bearing 01813-lA FIG. 33 Installing Thrust Bearing Retainer extends one and one-quarter inches from the rqck

13-42-13 Integral Power Steering Gear-Saginaw 13-42-13 TEFLON SEALS DRIVE PIN HOLE VALVE STUB SHAFT 0-RING SPOOL V DAMPENER 0-RING DRIVE PIN CAP END TON ION BAR BODY 0-RINGS VALVE

13-42-14 Integral Power Steering Gear-Saginaw 13-42-14 TOO L-T6SP-2D51 7-A TEFLONN-RING END OF TOOL MUST BE IN CONTACT WITH WOitM SHAFT / RACK IPISTON WORM SHAFT

13-46-1 Integral Power Rack and Pinion Steering Gear-FORD 13-46-1 Integral Power Rack and PART 13-46 Pinion Steering Gear- Ford Applies To Fairmont/Zephyr SUBJECT PAGE SUBJECT PAGE ADJUSTMENT DISASSEMBLY AND ASSEMBLY Cont’d. Rack Yoke Bearing Preload 46-12 Steering Gear 4614 Tie Rod Ends, Bellows and Tie Rod Ball Joint Sockets 46-14 DESCRIPTION Steering Gear

13-46-2 Integral Power Rack and Pinion Steering Gear-FORD 13-46-2 RUBBER INSULATOR NO. 2 CROSSMEMBER ---4 - 38593 b-S2 ROD END NUT - 33718-Si 00 3200 ASSY, BELLOWS GRIP THE ROD IN THIS AREA ONLV FOR SE FlING TOE. flU NOT GRIP ON THE TIE ROD

p Ce CD ‘a a

13-46-4 Integral Power Rack and Pinion Steering Gear-FORD 13-46-4 OPERATION ROTARY VALVE The rotary design control valve uses relative attached directly to the rack, and the housing functions rotational motion of the input shaft and valve sleeve to as the power cylinder. The oil in the opposite end of direct fluid flow. the power cylinder is forced to the control valve and back to the pump reservoir. When the steering wheel is turned, resistance of the wheels and the weight of the vehicle cause a torsion When the driver stops applying steering effort, the bar to deflect. This deflection changes the position of valve is forced back to a centered position by the the valve spool an

RIGHT TURN LEFT TURN OIL FLOW L.T. OIL FLOW AT. TUBE TO ALLOW AIR TRANSFER BETWEEN DELLOWS G2718-2A FIG. 3 Rack Movement "This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford

13-46-6 Integral Power Rack and Pinion Steering Gear-FORD 13-46-6 DIAGNOSIS Before any internal service is performed to the tions. The following conditions, possible causes rack and pinion power steering, diagnosis must be and resolutions will assist in performing the proper performed. Make sure that tire size is correct with repairs: matched tires front and rear inflated to specif lea- DIAGNOSIS GUIDE - FORD INTEGRAL POWER RACK AND PINION STEERING GEAR COMPLAINT POSSIBLE CAUSE RESOLUTION * Front End Wander I Tie rod ball socket loose/worn. * Replaco the tie rod/ball sDckot assembly. Front end wander is condition that

13-46-7 Integral Power Rack and Pinion Steering Gear-FORD 13-46-7 DIAGNOSIS GUIDE - FORD INTEGRAL POWER RACK AND PINION STEERING GEAR COMPLAINT POSSIBLE CAUSE RESOLUTION * Feedback Rutde, Chuckle, Knocking * Loose/worn tie rod ball socket. S Replace t rodbafl socket assembly. Noises in Stearing Gear Feedback is a condition that is noticed * Tie rod thrust bearing broken or worn. S Replace tie rod/ball socket assembly. when a car is driven over rough pavement and this roughness is felt in the steering * Oversize pinion shaft bushing in the gear S Replace gear housing. wheel by the driver. In a

____________ ______________ 13-46-8 Integral Power Rack and Pinion Steering Gear-FORD 13-46-8 DIAGNOSIS GUIDE - FORD INTEGRAL POWER RACK AND PINION STEERING GEAR COMPLAINT - POSSIBLE CAUSE RESOLUTION , Heavy Steering Efforts, Poor Assist * Leakage/loss of fluid due to leaking rack, * Replace rack seals, pinion seals, and/or pinion and/or input shaft seals. input shaft seals. A heavy effort and poor assist condition is recognized by the driver while turning * Low steerin

3-46-9 Integral Power Rack and Pinion Steering Gear-FORD 13-46-9 DIAGNOSIS GUIDE - FORD INTEGRAL POWER RACK AND PINION STEERING GEAR COMPLAINT POSSIBLE CAUSE RESULUTION * Poor Returnability-Sticky Feeling * Yoke bearing plug too tight. i Adjust yoke bearing preload to specifi Poor returnability isa condition that s cation- noticed when the vehic’e is in a turn and * Binding in valve assembly. * Replace input shaft and valve assemhly returns to center with effort from the dri

________ 13-46-10 Integral Power Rack and Pinion Steering Gear-FORD 13-46-10 DIAGNOSIS GUIDE - FORD INTEGRAL POWER RACK AND PINION STEERING GEAR COMPLAINT POSSIBLE CAUSE RESOLUTION * Loss of Power Assist * Piston disengaged from rack or improper * Replace rack assembly. When loss of power assist occurs, heavy depth of piston ring groove. steering effort 5 requhed by the driver to steer the car. * Gear housing oil seal leak. * Replace gear housing oil seals. * Damaged gear housing tube.

13-46-11 Integral Power Rock and Pinion Steering Gear-FORD 13-46-11 DIAGNOSIS GUIDE - FORD INTEGRAL POWER RACK AND PINION STEERING GEAR COMPLAINT POSSIBLE CAUSE RESOLUTION * External Leakage * 0-rings on rack bushing damaged or missing. * Replace U-rings. One of the most common conditions causing repeat repairs is fluid leaks. Make sure you * Oil seals damaged or mproperly installed: * Replace oil seals as required. clean off the steering gear first before any Pinion seal. steering year external leakage checks are performed. Rack hushing seal.

13-46-12 Integral Power Rock and Pinion Steering Gear-FORD 13-46-12 ADJUSTMENTS The powerrack and pinion steering gear provides for 6. Loosen the yoke plug locknut with wrench, Tool only one service adjustment. The gear must be removed T78P-3504-H Fig. 5. from the vehicle to perform this adjustment. Refer to 7. Loosen yoke plug with a 3/4" socket wrench.section on Gear Removal, 8. With the rack at the center of travel, tighten the RACK YOKE SEARING PRELOAD yoke plug to 45-50 in-lb Fig. 6. Clean the threads of the yoke plug prior

13-46-13 Integral Power Rack and Pinion Steering Gear-FORD 13-46-13 FIG. 5 Loosening/Tightening Yoke Plug Locknut A G212t1A FIG. 6 Adjusting Yoke Bearing Preload "This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

13-46-14 Integral Power Rack and Pinion Steering Gear-FORD 13-46-14 REMOVAL AND INSTALLATION STEERING GEAR 2. THE RUBBER INSULATORS 3K576 in Fig. 1 MUST Removal BE PUSHED COMPLETELY INSIDE THE GEAR HOUSING BEFORE THE INSTALLATION OF THE 1. Disconnect the negative battery cable from the battery. GEAR HOUSING ON NO.2 CROSSMEMBER. No gap is allowed between the insulator and the face 2. Remove the one bolt retaining the flexible coupling of the gear boss. A rubber lube such a Ruglyde or to the input

13-46-15 Integral Power Rack and Pi&on Steering Gear-FORD 13-46-15 Install tie rods. Hold one ball joint nut with a 1-5/ 16" open end or box wrench while torquing the other nut to specification with Tool, T74P-3504.tJ or equivalent Fig. 9. Both ends are torqued simultaneously by this method. 2. Support the ball housing with a block of wood.

13-46-16 Integral Power Rack and Pinion Steering Gear-FORD 13-46-16 TAP PIN LIGHTLY WITH A PLASTIC HAMMERN SUPPORT BALL HOUSIN WITH A OOD[N BLOCI 62125-lA G-2?z1-lA FIG. 10 Installing Roll Pin In Tie Rod Ball Joint FIG. 12 Installing Bellows Clamp 2. Mount gear in the bench mounted holding fixture, FRONT OP VEHICLE Tool, T571-500-B Fig. 4. 3. Remove the external pressure hnes from the gear

13-46-17 Integral Power Rack and Pinion Steering Gear-FORD 13-46-17 SNAP RING TOOL - TL T74P5O4.R G272-1 A 62730-lA FIG. 13 Removing/Installing Pinion Bearing FIG. 15 Removing/Installing Snap Ring Locknut SMALL SHARPI CHISEL G229-lA G2731-1A FIG. 14 Removing Input Shaft Dust Seal FIG. 16 RemovIng Input Shaft/Control Valve

13-46-18 Integral Power Rack and Pinion Steering Gear-FORD 13-46-18 SLIDE HAMMER TOOL TSOT-l-A TOOL-T18P-3504-E/ TOO TSSL-lO1-A -4 G2132-1A C 2734-lA FIG. 17 Activating Expander of Pinion Seal FIG. 19 Removing Pinion Bearing Remover Tool T78P-3504-E 12. The only serviceable com

Integral Power Rack and Pinion Steering Gear-FORD 13-46-19 i3_46_9 USE SPECKLED SEALS ONLY G277-lA G2735-1A FIG. 22 Seating Pinion Bearing FIG. 20 Removing Valve Sleeve Rings TOOL T7OP-3604G PINION OIL SEAL LIP TOWARDSTOOLN

13-46-20 Integral Power Rack and Pinion Steering Gear-FORD 13-46-20 SIZIN TUBE TOOL TISL-3511-A4 PUSHER TOOL T7SL-351 7.42 VALVE SLEEVE RING MANDREL TOOL SPACER TOOL TISL-3517-A1 t75L-351 7-A3

13-46-21 Integral Power Rack and Pinion Steering Gear-FORD 13-46-21 turns. If the number of turns is unequal, pull the TOOL 175L351741 valve ossembly out far enough to free the pinion MANDREL teeth. Rotate input shaft 60 degrees tone tooth in TOOL TJ5L-351 7-A4 direction which required less turns. Reinsert valve SIZI NC TUBE assembly and check if on center. Repeat procedure TOOL TI5L-351 1A7 f necessary. PUS

13-46-22 Integral Power Rack and Pinion Steering Gear-FORD 13-46-22 23. Install the external pressure lines, making sure the Q.rin9s are good and torqued to specification. DUST SEAL! TOOL -T78P.3504.D G2747IA FIG. 32 Applying Lubriplats Or Equivaisni To G2745-1A Shaft And Dust Seal FIG. 30 SeatIng Input Shaft Bearing TOOL T7BP3504D

13-46-23 Integral Power Rack and Pinion Steering Gear-FORD 13-46-23 GEAR HOUSING, RACK YOKE BEARING, RACK ASSEMBLY, RACK BUSHING AND OIL SEALS Disassembly 1. Remove the tie rod and socket assemblies from both ends of the rack and the input shaft and valve assembly as previously outlined in this Port. 2. Remove the yoke plug lock nut with Tool,

13-46-24 Integral Power Rack and Pinion Steering Gear-FORD 13-46-24 HOIJSINC END PLATE TOOL T78P-3504-J RACK BUSHING G27521A 02754-lA FIG. 37 Removing Rack And Rack Bushing From FIG. 39 Activating Expander On Rack Oil Seal Gear Housing Remover with slide hammer T5OT-100-A threaded into the expander end Fig. 40. Discard the seal. Note: On the first attempt

13-46-25 Integral Power Rack and Pinion Steering Gear-FORD i346-25 - TOQLT7 -19]O3C r G27S7-1A G2755-IA FIG. 40 Removing Rack Seal F!om Gear Housing FIG. 42 Removing 0-Ring Seals From Rock Bushing TOO L-T78P-3504-J TF4bO

13-46-26 Integral Power Rack and Pinion Steering Gear-FORD 13-46-26 2. Mark the center tooth space on the rack where it may be used to tap bushing in place. Install will be visible through the valve bore to facilitate retaining ring snap ring Fig. 36. Remove valve replacement. Use a quick drying paint stick protective sleeve. Fig. 44. 3. Install the rubber 0-ring in the groove of the rack piston. 4. Place a plastic 0-ring on replacer Tool, T74P-3504- G. Slide the toot and O-ring on the rack until it is adjacent to the piston. Slide the plastic 0-ring off the toot into the piston groove over the rubber 0- ring Fig. 45. 5. Pack rack teeth with specified grease. Apply a light coot of specified grease opposite the rack teeth

13-46-27 Integral Power Rack and Pinion Steering Gear-FORD 13-46-27 TOOL NO. - T74P-3504-K TOOL NO. - T74P4504-J TOO RACKSEAL LIP TOWARDSL-T74P-3504-FNRACK BUSHING RACK BUSHING G2703-1A

______________________ __________________________________________________________ ________ _________________________________________ ________________ ________________ 13-46-28 Integral Power Rack and Pinion Steering Gear-FORD 13-46-28 SPECIFICATIONS SPECIFICATION CHART - RACK & PINION - FORD Gear Ratio -- - 20.1 on Center 1 14.2 at_Stops

13-46-29 Integral Power Rack and Pinion Steerng Gear-FORD 13-46-29 Tool No. Description Tool No. Dewiption T74P-3504-F Outer Hack Oil Seal Replacer T78P-3504-8 Valve Body Puller TI4P-3504-G Plastic Ring Replacer T78P-3504-K Inner Aack Oil Seat Rep’acer T74P-3504-J flack Seal Protecting Sleeve Short TJ8P-3504-II Pinion Housing Yoke Nut Wrench T74P-3504-K Rack Seal Protecting Sleeve Long TJ8P-3504-G Pinion Uearinq Replacer T74P-3504-R Pinion Shaft Torque Adapter T78P-3504-J Rack Oil

13-47.1 Integral Power Rack and Pinion Steering Gear-TRW 1347-1 Integral Power Rack and 13-47 Pinion Steering Gear-TRW Applies To Mustang Il/Pinto/Bobcat, Fairmont/Zephyr SUBJECT PAGE SUBJECT PAGE ADJUSTMENTS 47-10 DISASSEMBLY AND ASSEMBLY ConI’d. Valve and Valve Housing 41-14 DESCRIPTION 41-1 OPERATION 41-5 REMOVAL AND INSTALLATION DIAGNOSIS 41-5

13-47-2 Integral Power Rack and Pinion Steering Gear-TRW 13-47-2 NO. 2 CROSSMEMBER RUBBER SPINDLE ARM INSULATOR WASHER GRIP TI ROD IN THIS AREA ONLY FOR SETTING TOE-DO NOT GRIP ON TIE ROD THREADS. G2S$-2A FIG. 1 Power Steering Gear Installation-TRW "This publication contains material that is reproduced and distributed under a license to

13-474 Integral Power Rack and Pinion Steering Gear-TRW 13-474 INPUT SHAFT TORSION BAR PUMP PORTS SUM? PORT CYLINDER ‘ IN ETUR NI PORTS PUMP PORT . IPRESSURCI LEFT TURN RIGHT TURN INPUT SHAFT ROTARY

13-47-4 Integral Power Rack and Pinion Steering Gear-TRW 13-47-4 P0 RT TO CV LIN0 ER PROM PUMP 4 PLACES IPRESSURE

___________ ________ 13-47-5 Integral Power Rack and Pinion Steering Gear-TRW 13-47-5 OPERATION ROTARY VALVE: When the driver stops applying steering effort, the The rotary design control valve uses relative valve is forced back to a centered position by the rotational motion of the input shaft and valve sleeve to torsion bar. When this occurs, pressure is equalized ondirect fluid flow. both sides of the piston and the front wheels tend to return to a straight ahead position. Refer to illustration When the steering wheel is turned, resistance of the Figs. 2 and 3 showing path of

13-47-6 Integral Power Rack and Pinion Steering Gear-TRW 13-47-6 DIAGNOSIS GUIDE - TRW INTEGRAL POWER RACK AND PINION STEERING GEAR COMPLAINT POSSIBLE CAUSE RESOLUTION * Feedlaeck Rattle, Chuckle. Knocking * Loose/worn tie rod ball socket. * Replace tie rod/ball socket assembly. Noises in Steering Gear Feedback is a condition that is noticed when * Tie rod thrust bearing broken or worn. * Replace tie rod/ball socket assembly. a car is driven over rough pavement and this roughness is felt in the steering wheel by the * Oversize pinion shaft bushing in the gear * Replace gear housing.

___________ _______ 13-47-7 Integral Power Rack and Pinion Steering Gear-TRW 13-47-7 DIAGNOSIS GUIDE - TRW INTEGRAL POWER RACK AND PINION STEERING GEAR COMPLAINT POSSIBLE CAUSE RESOLUTION * Heavy Steering Efforts, Poor Assist * Loose valve housing bolts causing leakage. * Tighten valve housing bolts to specification. A heavy effort and poor assist condition is * Leakage/loss of fluid due to leaking rack, * Replace rack seals, pinion seals, and/or input recognized by the driver while turning pinion and/or input shaft seals.

______ 13-47-8 Integral Power Rack and Pinion Steering Gear-TRW 13-474 DIAGNOSIS GUIDE - TRW INTEGRAL POWER RACK AND PINION STEERING GEAR COMPLAINT -- - POSSIBLE CAUSE RESOLUTION * Poor Returnability-Sticky Feeling * Yoke hearing plug too loose or too tight. * Adjust yoke bearing preload to specification. Poor returnabilify is a condition that is notjced when the vehicle is in a turn and * Binding in valve assembly. * Replace input shaft and valve assembly. returns to center wills effort from the - driver. In addition, when the driver retu

13-47-9 Integral Power Rack and Pinion Steering Gear-TRW 13-47-9 - DIAGNOSIS GUIDE -TRW INTEGRAL POWER RACK AND PINION STEERING GEAR * Loss of Power Assist * Piston disengaged from rack or improper * Replace rack assembly. When loss of power assist occurs, heavy depth of piston ring groove. steering effort is required by the driver to steer the car. * Gear housing oil seal leak. * Replace gear housing oil seals. * Damaged gear housing tube. * Replace gear housing.

13-47-10 Integral Power Rack and Pinion Steering Gear-TRW 13-47-10 DIAGNOSIS GUIDE - TRW INTEGRAL POWER RACK AND PINION STEERING GEAR COMPLAINT POSSIBLE CAUSE RESOLUTION * Ext&nal Lnkage * 0-rings, in the following areas, out or * Replace 0-rings as necessary. One of the most common conditions causing missing: Gear housing

13-47-11 Integral Power Rack and Pinion Steering Gear-TRW 13-47-11 2. Remove the power steering fluid from the power 8. Back off the yoke plug maximum of 45 degrees cylinder by removing the external pressure line until the torque required to initiate and sustain assemblies from the gear, and draining the fluid out rotation of the input shaft is 7-15 in-lbs. Input through the openings. torque should be checked with the gear in a 3. Install two long bolts and washers through the horizontal position so that the weight of the rack bushings, and attach to the bench mounted holding doesn’t affect the torque reading. fixture Tool No. T571-500-B Fig. 4. 9. Place the yoke plug locknut w

-13-47-12 Integral Power Rack and Pinion Steering Gear-TRW 13-47-12 ‘UT YOKE BEAMPNC YOKE BEARiNG TABS TOOL. NO. T77P.3504A 026742A FIG. 6 Loosening or Adjusting Yoke Bearing Plug "This publication contains material that is reproduced and

13-47-13 Integral Power Rack and Pinion Steering Gear-TRW 13-47-13 REMOVAL AND INSTALLATION STEERING GEAR Removal: adjustment has been made. Do not grip tie rod in area of threads. See Fig. 1 for illustration. 1. Disconnect the negative battery cable from the 10. Inspect gear for twisted bellows and improperly battery. installed clamps. Correct as necessary. 2. Remove the one bolt retaining the flexible coupling to the input shaft. TIE ROD ENDS AND BELLOWS 3. Leave the ignition key in the ON position and ra

13-47-14 Integral Power Rack and Pinion Steering Gear-TRW 13-47-14 BELLOWS REMOVAL - IN CHASSIS SPINDLE ARM PUT CHALK MARK ON FRONT SIDE, ORIENT TIE ROD APPLY TAPE OR PAINT IN THIS POSITION WHEN TO THIS AREA TO MARK RE-INSTALLING TIE-ROD LOCATION OF THE LOCK. END. NUT FOR RE-FNSTALLATION

13-47-15 Integral Power Rack and Pinion Steering Gear-TRW 13-47-15 the flat blocked tooth on the input shaft splines illustration of pinion seal and valve assembly to the valve housing face Fig. 14. It is important removal. Discard the oil pinion seal and any other that when subsequent assembly of the input shaft damaged or worn parts. Fig. 16 shows the is made, that the flat blocked tooth be aligned in disassembled components. the same position. 1 2. Remove the pinion bearing from the gear housing 9. The valve housing cannot be removed as a single with slide hammer T5OT-100-A, and attachm

13-47-16 Integral Power Rack and Pinion Steering Gear-TRW 13-47-16 TOOL T63P.9171-A LANGE BELLOWS CLAMP 02B75.ZA FIG. 9 Installing Large Bellows Clamps 15. Pry the input shaft dust seal out of the valve housing with a small sharp chisel. Pr

13-47-17 Integral .!!!r Rack and Pinion Steering Gear-TRW 13-47-17 LEFT TUnN TUBE RIGHT TURN TUBE FLARE INPUT SHAFT GASKETS DUST SEAL /- BEARING TEFLON 0-RINGS -

13-47-18 Integral Power Rack and Pinion Steering Gear-TRW 13-47-18 REMOVE ROIL FIN USING A STANDARD HOUSING EASIOUT TOOL ROLL PIN USE TOOL NO. 574 P3504-U

13-47-19 Integral Power Rack and Pinion Steering Gear-TRW 13-47-19 9. Prior to installing the valve and valve housing, outlined in the Adiusiment portion of this apply grease IubricantESA-M1C45-A orequiv procedure. aient to the pinion bushing, pinion bearing, and to the pinion teeth. GEAR HOUSING. RACK YOKE BEARING. RACK10. Move the rack to the left stop rack teeth exposed. ASSEMBLY. RACK BUSHING AND OIL SEALS Install the valve and valve housing assembly in the gear housing bore. The flat blocked tooth on the Disassembly: input shaft splines must be in the same relative 1. Remove the tie rod and socket assemblies from both position with the file or Chalk mark

13-47-20 Integral Power Rock and Pinion Steering Gear-TRW 13-47-20 PINION SEAL NON-METALLIC HAMMER INPUT SHAFT VALVE ASSEMBLY O25S22A FIG. 15 Removing Valve Asambly From Valve Housing RETAINING DUST SEAL BOLT AND

13-47-21 Integral Power Rack and Pinion Steering Gear-TRW 13-47-21 ATTACHMENT TOOL TSOL.10l-A TOOL NO. TSOT- 100-A PINION BEARING G24-lA 02686-IA FIG. 17 Removing Pinion Bearing FIG. 19 RemovIng Input Shaft Support Bearing Assembly 1. Place a high pressure oil seal on the inner rock oil seal replacer, T74P-3504-D, with the lip spring facing the tool

13-47-fl Integral Power Rack and Pinion Steering Gear-TRW 13-47-22 the leading end engages the internal oil seal 14. Place the rack bushing locknut over the rack and praperly. Position the sizing tool against the start it into the threads in the hausing bare. housing so that the plastic 0-ring is accurately 15. Insert rack bushing locknut wrench Tool T74P-3504- aligned with the housing bare Fig. 37. Push the B, over the exposed end of the rack and into the rack in until the long protective sleeve protrudes housing bore Fig. 30. Engage the tool drive tabs from the left side of the gear. Remove the sizing in the slots on the locknut and torque to tool and the long protective sleeve from the end of

13-47-23 Integral Power Rack and Pinion Steering Gear-TRW 13-47-23 VALVE HOUSING TOOL NO. T74P-3504-G TOOL NO. TOOL NO. fl4P-3504-N T71P-19703-C 02689-1* 0260

13-47-24 Integral Power Rack and Pinion Steering Gear-TRW 13-47-24 YOKE BEARING LOCK NUT VALVE HOUSING YOKE BEARING PLUG 02695-lA FIG. 28 Yoke Bearing Assembly PINION SEAL

13-47-25 Integral Power Rack and Pinion Steering Gear-TRW 73-47-25 RACK SOCKET WRENCH HOUSING ORIVE TAES TOOL NO. T74P-35O4-D 026942

13-47-26 Integral Power Rack and Pinion Steering Gear-TRW 13-47-26 02699-I A FIG. 32 Removing Inner Rack Oil Seal TOOL NO. TOOL NO. T74P-3604-C TSOT-lOO-A ALUMINUM RACK BUSHING 02700-2A FIG. 33 Removing Oil Seal From Rack Bushing

13-47-27 Integral Power Rack and Pinion Steering Gear-TRW 13-47-27 TOOL NO. T74P-3 504-0 OF TOOL RH. ENO OF GEAR HOUSING 02701-lA FIG. 34 Installing Inner Rack Oil Seal PLASTIC 0-RING RACK

13-47-28 Integral Power Rack and Pinion Steering Gear-TRW 13-47-28 TOOL NO. TI4P-3 504-K TOOL NO. T74P-35O4-J 02703-2A FIG. 36 Installing Protective Sleeves on Rock TOOL NO. T74P-35O4-H 1-

__________ ___________________ 13-47-29 Integral Power Rack and Pinion Steering Gear-TRW 13-47-29 PROTECTIVE SLEEVE TOOL NO. we 02707-IA FIG. 40 Installing Rack Bushing SPECIFICATIONS POWER RACK AND PINION STEERtNG GEAR - TRW Gear Ratio - - - 18.2 on Center

13-47-30 Integral Power Rack and Pinion Steering Gear-TRW 13-47-30 Tool No. Description Tool No. Description T74P-3504-C Rack Oil Seal Remover T74P-3504-R Pinion Shaft Torque Adapter TI4P-3504-0 Inner Rack Oil Seal Replacer T74P-3504-IJ Pinion Housing Yoke Plug Nut Wrench 114P-3504-E Rack Bushing Holding Tool TI4P-3504-Y Spring Scale 0-10 Lbs. TI4P-3504-F Outer Rack Oil Seal Replacer T5OTIOO-A Slide Hammer T74P-3504-G Plastic Ring Replacer TS7L-500-B Bench Mount TJ4P-3504-H

13-51-1 Power Steering Pump-Ford Model CII 13-51-1 Power Steering Pump- 1’S Ford Model CII Applies To All Cars, Except Lincoln Continental and Mark V SUBJECT PAGE SUBJECT PAGE ADJUSTMENT 51-5 REMOVAL AND INSTALLATION Cont.’dj Power Steering Pump Reservoir 51-6 DESCRIPTION 51-1 Rotor Shaft Seal 51-6 SPECIFICATIONS AND DISASSEMBLY AND ASSEMBLY 51-13 SPEC

13-51-2 Power Steering Pump-Ford Model CII 13-51-2 PUMP HOUSING PLATE - 30643 SPRING - SEAL - IJPPER PLATE 30586 38757 1-5100 - 34645 02560.2A FIG. 2 Ford Model C II Power Steering Pump-Exploded View "This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction

______________ 13-514 Power Steering Pump-Ford Model CII 13-51-3 TEST PROCEDURE: ROTUNDA FLOW/PRESSURE POWER continue the diagnosis. Check chart for flow STEERING PUMP ANALYZER OR and relief pressure against the model pump EQUIVALENT being tested. b If pressure B is above 150 psi, check hoses for The test procedure using the Rotunda Flow! restrictions.Pressure Power Steering Analyzer Special Tool No. 970-001 or equivalent provides a method for NOTE: On non-integral power steering, jiggle checking the complete power steering system. The the steering wheel t

13-51-4 Power Steering Pump-Ford Model CII 13-51-4 CU POWER STEERING PUMP POWER STEERING POWER STEERING GEAR ROSE HIGH PRESSURE TYPICAL INSTALLATION CU POWER STEERING PUMP UPPER INSULATOR ASSEMBLY HYDROBOOST

13-51-5 Power Steering Pump-Ford Model CII 13-51-5 ADJUSTMENTS PUMP BELT TENSION pump shaft. Do nat apply in and out pressure

13-51-6 Power Steering Pump-Ford Model CII 13-514 pressure hose assembly. Use of an open end NOTE: Do not damage the bushing, housing, wrench to tighten the nut can deform the tube or the rotor shaft. nut hex which may result in improper torque Installation: and may make further servicing of the system difficult. 1. Remove the shim stock from the rotor shaft. 4. Connect the return hose to the pump and tighten 2. Apply Motorcraft adhesive No. D5AZ-19554-A the clamp. Raise vehicle an hoist and connect lower Loctite No. 242 or 271 or equivalent, to the return line hydroboost only.

13-51-7 Power Steering Pump-Ford Model CII T3-51-7 control valve and spring. Discard all seals Fig. 11. Remove the fiberglass reservoir Figs. 12-13. Discard 0-ring seal on pump housing Fig. U. NOTE: Do not hammer on the reservoir. Installation: 1. install a new 0-ring seal on the pump housing. 2. Apply petroleum lelly to the reservoir 0-ring seal and the inside edge of the reservoir. Do not twist the 0-ring seal Fig. 15. 3. Place the reservoir over the pump and align the outlet fitting hole in the reservoir with the hole in the valve cover. 4. Place new 0-ring seals on the outlet fitting. Install the flow control spring, flow control valve and outlet fitting into the reservoir and valve cover. Torque the fitting to proper torque specif

08Dd.3E60-dA 70 AMF, ALT- ONLY WITH A/d 55730-52 3642 OBDC3E670-BA FT-LB

56546-52 12-lB FT-LB 34976-S2 12-18 FT-LB a3L I2SOCID ENGIII1 CALIFORNIA