Section 11-02: Steering System, Power
1993 Mustang Workshop Manual
DISASSEMBLY AND ASSEMBLY

Gear Housing, Rack Yoke Plug, Rack Assembly, Rack Bushing and Oil Seals

Tools Required:

 

Disassembly

  1. Remove the yoke plug locknut with Pinion Housing Yoke Locknut Wrench T78P-3504-H. Remove the yoke plug with a 3/4-inch socket wrench.
  1. Remove the yoke spring and the yoke from the gear housing. The yoke may be gripped by the spring guide post with a pair of pliers.
  1. Remove input shaft and valve assembly from gear housing. Remove tie rod and socket assemblies from both ends of the rack.
  1. Working from the RH side of the gear (opposite pinion end), push the rack in just far enough to facilitate removal of snap ring.
  1. Remove snap ring from RH end of housing.

     CAUTION: Do not hammer on the rack, aluminum rack bushing or housing. Damage may occur.

  1. Slowly pull the rack out of the RH side of the housing until the rack piston contacts the aluminum rack bushing. Apply pulling effort on the rack until the bushing is withdrawn from the housing. Remove the rack from the housing.

    NOTE: On the first attempt, the nylon ring may pull out of the seal, leaving the seal in the gear. Repeat the procedure, and the seal will come out.

  1. To remove the internal high-pressure rack oil seal, insert Rack Oil Seal Remover T78P-3504-J into the housing until it bottoms. Activate the expander with a wrench until the expander fully tightens. Remove the tool with the oil seal from the housing using Impact Slide Hammer T50T-100-A threaded into the expander end. Discard the seal.











  1. Remove the plastic O-ring and the rubber O-ring from the rack piston with O-Ring Tool T71P-19703-C.
  1. Insert the rack bushing into the Rack Bushing Holding Tool T78P-3504-L, seal end first. Place the tool and bushing in vise. With Rack Oil Seal Remover T78P-3504-J and Impact Slide Hammer T50T-100-A remove the seal.



  1. Remove the rubber O-ring from the bushing with O-Ring Tool T71P-19703-C.



 

Assembly

  1. Mark the center tooth space on the rack where it will be visible through the valve bore to facilitate valve replacement. Use a quick-drying paint stick.



  1. Install the rubber O-ring in the groove of the rack piston.
  1. Slide Teflon Ring Replacer T74P-3504-G on the rack until it seats on the piston. Slide the plastic O-ring over the tool into the piston groove over the rubber O-ring.



  1. Remove plastic insert from rack seal. Save insert for installation.



  1. Install Rack Seal Protector T85L-3504-B over rack teeth.
  1. Lubricate rack seal protector and rack with power steering fluid.
  1. Install seal with lip toward piston. Push seal all the way against piston. Remove rack seal protector.



  1. Install plastic insert in rack seal.



  1. Pack rack teeth with steering gear lubricant. Apply light coat of steering gear lubricant to yoke contact area, back of rack teeth.



  1. Lubricate piston seal and rack seal outside diameter with power steering fluid.
  1. Install Sizing Tool T78P-3504-M into end of gear housing.



  1. Install rack, taking care not to scratch housing piston bore.
  1. Carefully push piston through sizing tool. Continue pushing on rack until it bottoms. Remove sizing tool.
  1. Seat rack seal with rack by driving end of rack with a drift or bar stock and plastic mallet. DO NOT remove rack.



  1. Move rack so it is approximately centered in housing.
  1. Thread Rack Seal Protective Sleeve T74P-3504-J over threads on RH side of rack. Apply power steering fluid to protective sleeve.
  1. Install the rubber O-ring on the aluminum rack bushing.
  1. Apply Steering Gear Grease C3AZ-19578-A (ESW-M1C87-A) or equivalent to the outer rack oil seal. With Outer Rack Seal Replacer T74P-3504-F, install the high-pressure oil seal in the rack bushing. The lip spring must face the inside of the bushing.



  1. Lubricate the short protective sleeve on the rack end and the rubber O-rings on the rack bushing with Steering Gear Grease C3AZ-19578-A (ESW-M1C87-A) or equivalent.
  1. Start the bushing, seal facing out, on the rack. Pass the bushing and seal over the protecting sleeve and into the housing bore. Place end plate against the rack bushing. With Teflon Ring Sizing Tool T78P-3504-M, apply hand pressure to the end plate and rack bushing until the bushing seats in the gear housing. If the rack bushing will not seat with hand pressure, a 1-1/8-inch deep socket (or larger) and a plastic mallet may be used to tap bushing in place. Install retaining ring (snap ring). Remove protective sleeve.
  1. Install the rod assemblies. Tighten both tie rod ball joint nuts simultaneously to 75-88 Nm (55-65 lb-ft) by holding one and turning the other.
  1. Install roll pins in ball joint nuts by lightly tapping with hammer until seated.
  1. Install the input shaft and valve assembly as outlined.
  1. Fill yoke plug hole with 57 grams (2 oz) Steering Gear Grease C3AZ-19578-A (ESW-M1C87-A) or equivalent. Insert plastic yoke, spring, plug and locknut. Adjust yoke plug preload as outlined.
  1. Apply Steering Gear Grease C3AZ-19578-A (ESW-M1C87-A) or equivalent to groove in tie rods where the bellows clamp to the tie rods. This is required to keep the bellows from twisting during toe-in adjustment.
  1. Install bellows and pressure equalizer tube. Install clamps retaining the bellows to the gear housing.
  1. Install clamps retaining the bellows to the tie rods.
  1. Install jam nuts and tie rod ends on the tie rods.