Connecting Rod and Bellows—Front Wheel Spindle

Disassembly

1. Install two long bolts and washers through the bushings, and retain to Bench Mounted Holding Fixture T57L-500-B.

2. Loosen the jam nuts on the outer ends of the front wheel spindle connecting rods (3280) adjacent to the front wheel spindle connecting rod or ends (3A130) , and remove the front wheel spindle connecting rod or ends and jam nuts.

    CAUTION: Use care not to damage the front suspension steering ball stud dust seals (3332) as internal damage to rack may result.

3. Remove the four clamps retaining the front suspension steering ball stud dust seals to the steering gear housing (3548) and the front wheel spindle connecting rods . Discard the clamps if damaged or excessively corroded.

4. Remove the front suspension steering ball stud dust seals along with the power steering gear rack tube (3K762).

   NOTE: For units equipped with rivets in place of the coiled pins, perform Steps 7 and 8:

5. If pinion requires removal, remove pinion before proceeding as outlined.

6. Using Locknut Pin Remover D81P-3504-N or equivalent, remove coiled lockpins from inner front wheel spindle connecting rods .
   
   
   
   

7. With a sharp chisel, gently tap around rivet head so it lifts away from front wheel spindle connecting rod . Use caution so the center pin is not sheared off.
   
   
   
   

8. Use side cutters to pry out drive pin.
   
   
   
   

9. If pinion was not removed in Step 5, remove steering gear housing from the holding fixture and lay on the bench before proceeding. This prevents gear teeth damage from rack twisting when removing the front wheel spindle connecting rods in Step 10.

   NOTE: Some steering gear (3504) assemblies may contain one or two rack travel restrictors on each side of the rack. The restrictors are split nylon washers and, if required, can easily be removed from the rack following Tie Rod Removal. Restrictors may be reused unless heavily worn.

10. Position rack so that several rack teeth are exposed. Hold rack with an adjustable wrench on the end teeth only, while loosening ball joint nuts with Nut Wrench T74P-3504-U.
    
    
    
    

Assembly

1. If pinion is installed, turn steering gear against or near LH stop and hold rack with adjustable wrench nearest the rack end. Tighten each ball joint assembly separately using Nut Wrench T74P-3504-U to 75-88 Nm (55-65 lb-ft).

2. If pinion was removed, hold one ball joint nut with a 1-5/16 inch open-end or box wrench while tightening the other nut to 75-88 Nm (55-65 lb-ft) with Nut Wrench T74P-3504-U. Both ends are tightened simultaneously by this method.

3. Support the ball housing with a wood block. Install new roll pins in the tie rod ball housing by tapping lightly with a plastic hammer.
   
   
   
   

4. If pinion was removed, install pinion as outlined.

5. Thoroughly clean the rack and housing bore of any foreign material. Any abrasive material is extremely harmful to the high-pressure oil seals.

6. Apply Steering Gear Grease C3AZ-19578-A or equivalent meeting Ford specification ESW-M1C87-A to groove in the rods where the bellows clamp to the front wheel spindle connecting rod . This allows for toe-in adjustment without twisting the front suspension steering ball stud dust seals .

7. Install front suspension steering ball stud dust seals and power steering gear rack tube . Install clamps retaining the front suspension steering ball stud dust seals to the steering gear housing and tighten to 2.3-3.4 Nm (1.7-2.5 lb-ft).
   
   
   
   

8. Install new clamps retaining front suspension steering ball stud dust seals to front wheel spindle connecting rods .

9. Install the jam nuts on the front wheel spindle connecting rods .

10. Apply Disc Brake Caliper Slide Grease D7AZ-19590-A or equivalent meeting Ford specification ESA-M1C172-A to tie rod threads.

11. Install front wheel spindle connecting rod or ends on the front wheel spindle connecting rods .