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

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.

2. Remove the yoke spring and the yoke from the steering gear housing (3548) . The yoke may be gripped by the spring guide post with a pair of pliers.

3. Remove power steering gear input shaft and control (3D517) assembly from steering gear housing . Remove front wheel spindle connecting rod (3280) and front wheel spindle connecting rod or end (3A130) assemblies from both ends of the steering gear sector shaft (3575) .

4. Working from the RH side of the steering gear (3504) (opposite pinion end), push the steering gear sector shaft in just far enough to facilitate removal of snap ring.

5. Remove snap ring from RH end of steering gear housing .

    CAUTION: Do not hammer on the steering gear sector shaft , aluminum rack bushing or housing or damage may occur.

6. Slowly pull the steering gear sector shaft out of the RH side of the steering gear housing until the rack piston contacts the aluminum rack bushing. Apply pulling effort on the steering gear sector shaft until the bushing is withdrawn from the steering gear housing . Remove the steering gear sector shaft from the steering gear housing .

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

7. 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.
   
   
   
   
   
   
   
   
   
   
   
   

8. Remove the plastic o-ring (3Z728) and the rubber o-ring from the rack piston with O-Ring Tool T71P-19703-C.

9. 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.
   
   
   
   

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

Assembly

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

2. Install the rubber o-ring in the groove of the rack piston.

3. Slide Teflon Ring Replacer T74P-3504-G on the steering gear sector shaft until it seats on the piston. Slide the plastic O-ring over the tool into the piston groove over the rubber o-ring .
   
   
   
   
   

   Item	Part Number	Description
   1	—	Rack Piston (Part of 3575)
   2	3575	Steering Gear Sector Shaft
   3	—	Rubber O-Ring (Part of 3E501)
   4	T74-3504-G	Teflon® Ring Replacer
   5	—	Plastic O-Ring (Part of 3E501)

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

5. Install Rack Seal Protector T85L-3504-B over rack teeth.

6. Lubricate rack seal protector and steering gear sector shaft with power steering fluid.

7. Install seal with lip toward piston. Push seal all the way against piston. Remove rack seal protector.
   
   
   
   

8. Install plastic insert in rack seal.
   
   
   
   

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

10. Lubricate piston seal and rack seal outside diameter with power steering fluid.

11. Install Sizing Tool T78P-3504-M into end of gear steering gear housing .
    
    
    
    

12. Install steering gear sector shaft , taking care not to scratch housing piston bore.

13. Carefully push piston through sizing tool. Continue pushing on steering gear sector shaft until it bottoms. Remove sizing tool.

14. Seat rack seal with steering gear sector shaft by driving end of steering gear sector shaft with a drift or bar stock and plastic mallet. DO NOT remove steering gear sector shaft .
    
    
    
    

15. Move steering gear sector shaft so it is approximately centered in steering gear housing .

16. Thread Rack Seal Protective Sleeve T74P-3504-J over threads on RH side of rack. Apply power steering fluid to protective sleeve.

17. Install the rubber o-ring on the aluminum rack bushing.

18. Apply Steering Gear Grease C3AZ-19578-A or equivalent meeting Ford specification ESW-M1C87-A 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.
    
    
    
    

19. 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 or equivalent meeting Ford specification ESW-M1C87-A.

20. Start the bushing, seal facing out, on the steering gear sector shaft . 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 steering 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.

21. Install the front wheel spindle connecting rod assemblies. Tighten both front wheel spindle connecting rod nuts simultaneously to 75-88 Nm (55-65 lb-ft) by holding one and turning the other.

22. Install roll pins in front wheel spindle connecting rod nuts by lightly tapping with hammer until seated.

23. Install the power steering gear input shaft and control assembly as outlined.

24. Fill yoke plug hole with 57 grams (2 oz) Steering Gear Grease C3AZ-19578-A or equivalent meeting Ford specification ESW-M1C87-A. Insert plastic yoke, spring, plug and locknut. Adjust yoke plug preload as outlined.

25. Apply Steering Gear Grease C3AZ-19578-A or equivalent meeting Ford specification ESW-M1C87-A to groove in front wheel spindle connecting rods where the bellows clamp to the front wheel spindle connecting rods . This is required to keep the front suspension steering ball stud dust seals (3332) from twisting during toe-in adjustment.

26. Install front suspension steering ball stud dust seals and pressure equalizer tube. Install clamps retaining the bellows to the gear housing.

27. Install clamps retaining the bellows to the tie rods.

28. Install jam nuts and tie rod ends on the tie rods.