Ford Aerostar 1986-1997 Repair Guide

Manual Rack and Pinion



See Figure 1

Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the manual rack and pinion mounting hardware

  1. Rotate the steering gear from lock to lock (entire gear travel) and record the number of steering wheel rotations. Divide the number of steering wheel rotations by two to get the required number of turns to place the steering wheel in the centered (straight ahead) position. From one lock position, rotate the steering wheel the required number of turns to center the steering rack.
  3. Raise the vehicle and support it safely, then remove the bolt retaining the intermediate steering column shaft to the steering gear pinion. Separate the shaft from the pinion.
  5. Remove and discard the cotter pin retaining the nut to the tie rod ends. Remove the nut, then separate the tie rod ends from the spindle arms using remover tool T64P-3590-F, or equivalent.
  7. Support the steering gear and remove the two nuts, bolts and washers retaining the gear to the crossmember. Remove the gear and, if required, remove the front and rear insulators from the gear housing.

To install:
  1. Install the front and rear insulators in the gear housing, if removed.
  3. Position the steering gear on the crossmember, then install the nuts, bolts and washers. Tighten the nuts to 65-90 ft. lbs. (88-122 Nm).
  5. With the steering gear, steering wheel and front wheels in the centered position, attach the tie rod ends to the spindle arms. Install the nuts and tighten them to 52-73 ft. lbs. (70-100 Nm). If required, advance the castle nuts to the next castellation and install new cotter pins. Do not loosen the nuts to line up the cotter pin hole.

Make sure the tie rod ball studs are seated in the spindle tapers to prevent rotation while tightening the nut.

  1. Connect the steering column intermediate shaft to the gear pinion, then install the bolt and tighten it to 30-42 ft. lbs. (41-57 Nm).
  3. Have the toe-in and front end alignment checked at a qualified service shop.