AutoZone 2011 Volvo Truck XC60 3.2 2WD 3.2L MFI DOHC 6cyl | Repair Guides | Suspension & Steering | Steering | Power Rack And Pinion Steering Gear | AutoZone.com

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    Ford Thunderbird/Cougar 1983-1997 Repair Guide

    Power Rack And Pinion Steering Gear

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    ADJUSTMENTS



    The power rack and pinion steering gear provides for only one service adjustment. The gear must be removed from the vehicle to perform this adjustment.

    Rack Yoke Plug Preload
    1. Clean the exterior of the steering gear thoroughly.
    2.  
    3. Install two long bolts and washers through the bushing, and attach to the bench mounted holding fixture, Tool T57L-500-B or equivalent.
    4.  
    5. Do not remove the external pressure lines, unless they are leaking or damaged. If these lines are removed, they must be replaced with new lines.
    6.  
    7. Drain the power steering fluid by rotating the input shaft lock-to-lock twice using Tool T74P-3505-R or equivalent. Cover ports on valve housing with shop cloth while draining gear.
    8.  
    9. Insert an inch-pound torque wrench with maximum capacity of 30-60 inch lbs. into the input shaft torque adapter, Tool T74P-3504-R or equivalent. Position the adapter and wrench on the input shaft splines.
    10.  
    11. Loosen the yoke plug locknut with wrench, Tool T78P-3504-H or equivalent.
    12.  
    13. Loosen yoke plug with a 3 / 4 in. socket wrench.
    14.  
    15. With the rack at the center of travel, tighten the yoke plug to 45-50 inch lbs. Clean the threads of the yoke plug prior to tightening to prevent a false reading.
    16.  
    17. Back off the yoke plug approximately 1 / 8 turn (44° minimum to 54° maximum) until the torque required to initiate and sustain rotation of the input shaft is 7-18 inch lbs.
    18.  
    19. Place Tool T78P-3504-H or equivalent on the yoke plug locknut. While holding the yoke plug, tighten the locknut to 44-66 ft. lbs. Do not allow the yoke plug to move while tightening or the preload will be affected. Recheck input shaft torque after tightening locknut.
    20.  
    21. If the external pressure lines were removed, they must be replaced with new service line. Remove the copper seals from the housing ports prior to installation of new lines.
    22.  

    REMOVAL & INSTALLATION



    1983-88 Vehicles

    See Figure 1

    1. Disconnect the negative battery cable.
    2.  
    3. Remove the one bolt retaining the flexible coupling to the input shaft.
    4.  
    5. Leave the ignition key in the ON position, and raise the vehicle on a hoist.
    6.  
    7. Remove the two tie rod end retaining cotter pins and nuts. Separate the studs from the spindle arms, using the ball joint separator tool.
    8.  
    9. Support the steering gear, and remove the two nuts, insulator, washers, and bolts retaining the steering gear to the No. 2 crossmember. Lower the gear slightly to permit access to the pressure and return line fittings.
    10.  
    11. Disconnect the pressure and return lines from the steering gear valve housing. Plug the lines and parts in the valve housing to prevent entry of dirt.
    12.  
    13. Remove the steering gear assembly from the vehicle.
    14.  



    Click image to see an enlarged view

    Fig. Fig. 1: Power steering gear assembly-1983-88 vehicles

    To install:
    1. Support and position the steering gear, so that the pressure and return line fittings can be connected to the valve housing. Tighten the fittings to 15-20 ft. lbs. (20-27 Nm). The design allows the hoses to swivel when tightened properly. Do not attempt to eliminate looseness by overtightening, since this can cause damage to the fittings.
    2.  

    The rubber insulators must be pushed completely inside the gear housing before the installation of the gear housing on the No. 2 crossmember.

    1. No gap is allowed between the insulator and the face of the gear boss. A rubber lubricant should be used to facilitate proper installation of the insulators in the gear housing. Insert the input shaft into the flexible coupling, and position the steering gear to the No. 2 crossmember. Install the two bolts, insulator washers, and nuts. Tighten the two nuts to 80-100 ft. lbs. (108-136 Nm).
    2.  
    3. Connect the tie rod ends to the spindle arms, and install the two retaining nuts. Tighten the nuts to 35-45 ft. lbs. (47-61 Nm), then, after tightening to specification, tighten the nuts to their nearest cotter pin castellation, and install two new cotter pins.
    4.  
    5. Lower the vehicle, and install the one bolt retaining the flexible coupling to the input shaft. Tighten the bolt to 18-23 ft. lbs. (24-31 Nm).
    6.  
    7. Turn the ignition key to the OFF position.
    8.  
    9. Connect the negative battery cable.
    10.  
    11. Remove the coil wire.
    12.  
    13. Fill the power steering pump reservoir.
    14.  
    15. Engage the starter, and cycle the steering wheel to distribute the fluid. Check the fluid level and add as required.
    16.  
    17. Install the coil wire, start the engine, and cycle the steering wheel. Check for fluid leaks.
    18.  
    19. If the tie rod ends were loosened, have the wheel alignment checked.
    20.  

    1989-96 Vehicles

    See Figures 2 and 3

    1. Raise and safely support the vehicle with jackstands.
    2.  
    3. Remove both front wheel and tire assemblies.
    4.  
    5. Remove the cotter pins at the outer tie rod ends, then remove the castellated nuts from each end. Discard the cotter pins.
    6.  
    7. Separate the tie rod ends from the left and right side knuckle (spindle) using Tie Rod End Remover TOOL-3290-D or equivalent.
    8.  
    9. Place a suitable drain pan under the vehicle. Disconnect and plug the power steering return hose.
    10.  
    11. Disconnect the power steering pressure hose at the intermediate fitting and position out of the way.
    12.  



    Click image to see an enlarged view

    Fig. Fig. 2: Disconnect the power steering pressure hose at the intermediate fitting and position out of the way

    1. Remove the steering shaft retaining bolt.
    2.  
    3. Remove the rack-to-subframe bolts and nuts. Access the nuts through the hole in the front crossmember.
    4.  
    5. Lower the power steering short rack as necessary, to remove the pressure line inlet tube. Remove and discard the plastic seal on the inlet tube.
    6.  
    7. Cut the tie strap securing the power steering pressure hose to each tube.
    8.  
    9. Remove the power steering short rack from the vehicle.
    10.  



    Click image to see an enlarged view

    Fig. Fig. 3: Power steering gear assembly-1995 vehicle shown

    To install:
    1. Install a new seal on the pressure line.
    2.  
    3. Install the steering gear insulator from the rear side of the steering gear housing, making sure they are fully seated. Use a suitable rubber lubricant to aid in installation.
    4.  
    5. Install and position the power steering short rack to the front crossmember.
    6.  
    7. Install the pressure line in the intermediate fitting.
    8.  
    9. Align the steering gear input shaft to allow the power steering short rack to completely seat on the front crossmember.
    10.  
    11. Install the steering gear input shaft retaining bolts and nuts. Tighten the bolts to 100-144 ft. lbs. (135-195 Nm).
    12.  
    13. Install the steering shaft flex coupling retaining bolt and tighten to 30-42 ft. lbs. (41-57 Nm).
    14.  
    15. Secure the power steering pressure hose to the power steering left turn pressure hose with a new tie strap.
    16.  
    17. Connect the power steering pressure hose.
    18.  
    19. Attach the power steering return hose, then tighten the clamp to 12-18 ft. lbs. (1.4-2.0 Nm).
    20.  
    21. Install the outer tie rod ends to the left and right knuckles and install castellated nuts at each ends. Tighten the nuts to 39 ft. lbs. (53 Nm). Continue to tighten the nuts until the castellations line up with the stud bores.
    22.  
    23. Install new cotter pins through the stud bores at each tie rod end.
    24.  
    25. Install both wheel and tire assemblies. Tighten the lug nuts to 85-105 ft. lbs. (115-142 Nm).
    26.  
    27. Carefully lower the vehicle, then fill the power steering system with the correct amount and type of fluid.
    28.  
    29. Connect the negative battery cable, then have the alignment checked at a reputable repair shop.
    30.  

     
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