Except 1990-92 Taurus and Sable LX with 3.8L Engine, 1993-95 Taurus GL (high series only), LX and SHO models, and SablesRACK YOKE PLUG CLEARANCE
The rack yolk clearance adjustment is not a normal service adjustment. It is only required when the input shaft and valve assembly is removed.
- Remove the steering gear from the vehicle. Clean the exterior of the steering gear thoroughly.
- Install the steering gear in a suitable holding fixture. Do not remove the external transfer tubes unless they are leaking or damaged. If these lines are removed, they must be replaced with new ones.
- Drain the power steering fluid by rotating the input shaft lock-to-lock twice, using a suitable tool. Cover the ports on the valve housing with a shop cloth while draining the gear to avoid possible oil spray.
- Insert an inch pound torque wrench with a maximum capacity of 60 inch lbs. (6.77 Nm) into the Pinion Shaft Torque Adapter T74P-3504-R or equivalent. Position the adapter and wrench on the input shaft splines.
- Loosen the yoke plug locknut and then the yoke plug.
- Clean the threads of the yoke plug before tightening, to prevent a false reading. With the rack at the center of travel, tighten the yoke plug to 45-50 inch lbs. (5.0-5.6 Nm).
- Back off the yoke plug approximately 1 / 8 turn (44-54 degrees) until the torque required to initiate and sustain rotation of the input shaft is 7-18 inch lbs. (0.78-2.03 Nm).
- Place a suitable wrench on the yoke plug locknut. While holding the yoke plug, tighten the locknut to 44-66 ft. lbs. (60-89 Nm). Do not allow the yoke plug to move while tightening or preload will be affected. Check the input shaft torque as in step 7 after tightening the locknut.
- Install the steering gear.
REMOVAL & INSTALLATION
Except 1990-92 Taurus and Sable LX with 3.8L Engine, 1993-95 Taurus GL (high series only), LX and SHO models, and Sables
See Figures 1, 2 and 3
- Disconnect the negative battery cable. Working from inside the vehicle, remove the nuts retaining the steering shaft weather boot to the dash panel.
- Remove the bolts retaining the intermediate shaft to the steering column shaft. Set the weather boot aside.
- Remove the pinch bolt at the steering gear input shaft, then remove the intermediate shaft. Raise the vehicle and support safely.
- Remove the left front wheel and tire assembly. Remove the steering shaft U-joint/heat shield. Cut the bundling strap retaining the lines to the gear.
- Remove the tie rod ends from the spindles. Place a drain pan under the vehicle, then remove the hydraulic pressure and return lines from the steering gear.
The pressure and return lines are on the front of the housing. Do not confuse them with the transfer lines on the side of the valve.
- Remove the nuts from the gear mounting bolts. The bolts are pressed into the gear housing and should not be removed during gear removal.
- Push the weather boot end into the vehicle and lift the gear out of the mounting holes. Rotate the gear so the input shaft will pass between the brake booster and the floor pan. Carefully start working the steering gear out through the left fender apron opening.
- Rotate the input shaft so it clears the left fender apron opening, then complete removal of the steering gear. If the steering gear seems to be stuck, check the right tie rod to ensure the stud is not caught on anything.
- Install new plastic seals on the hydraulic line fittings.
- Insert the steering gear through the left fender apron. Rotate the input shaft forward to completely clear the fender apron opening.
- To allow the gear to pass between the brake booster and the floorpan, rotate the input shaft rearward. Align the steering gear bolts to the bolt holes. Install the mounting nuts and tighten them to 85-100 ft. lbs. (115-135 Nm). Lower the vehicle.
- From inside the engine compartment, install the hydraulic pressure and return lines. Tighten the power steering pressure line to 15-25 ft. lbs. (20-35 Nm) and the return line to 15-25 ft. lbs. (20-35 Nm).
Swivel movement of the lines is normal when the fittings are properly tightened.
- Raise and safely support the vehicle. Secure the power steering pressure and return lines to the transfer tube with the bundle strap. Install the steering shaft U-joint/heat shield.
- Install the tie rod ends to spindles. Tighten the castle nuts to 35 ft. lbs. (48 Nm) and, if necessary, tighten the nuts a little bit more to align the slot in the nut for the cotter pin. Install the cotter pin.
- Install the left front wheel and tire assembly, then carefully lower the vehicle. Working from inside the vehicle, pull the weather boot end out of the vehicle and install it over the valve housing. Install the intermediate shaft to the steering gear input shaft. Install the inner weather boot to the floor pan.
- Install the intermediate shaft to the steering column shaft. Fill the power steering system.
- Connect the negative battery cable. Check the system for leaks and proper operation. Adjust the toe setting as necessary.
1990-92 Taurus LX and Sable with 3.8L Engine, 1993-95 Taurus GL (high series only), LX and SHO models, and Sables
See Figures 4, 5, 6, 7, 8, 9 and 10
The Variable Assist Power Steering (VAPS) system used on these vehicles consists of a micro-processor based module, a power rack and pinion steering gear, an actuator valve assembly, hose assemblies and a high efficiency power steering pump.
- Disconnect the negative battery cable.
- From inside the vehicle, remove the nuts securing the steering column tube boot to the cowl panel.
- Remove the two bolts retaining the steering column gear input shaft coupling to the power steering gear shaft and yoke assembly.
- Set the steering column tube boot aside. Remove the pinch bolt at the power steering gear shaft and yoke assembly, then remove the steering column gear input shaft coupling.
- Raise the vehicle and support safely. Remove the front wheel and tire assemblies. Support the vehicle under the rear edge of the subframe with jack stands.
- Remove the tie rod cotter pins and nuts. Remove the left and right-side tie rod ends from the steering knuckle.
- Mark the position of the jam nut (to maintain the alignment), then remove the tie rod ends from the spindle tie rod.
- Remove the nuts from the gear-to-subframe attaching bolts.
- Remove the rear subframe-to-body attaching bolts.
- Remove the exhaust pipe-to-catalytic converter attachment.
- Lower the vehicle carefully until the subframe separates from the body approximately 4 in. (102mm).
- Remove the heat shield band, then fold the shield down.
- Disengage the VAPS electrical connectors from the actuator assembly.
- Rotate the gear to clear the bolts from the subframe and pull to the left to facilitate line fitting removal.
- Position a suitable drain pan under the vehicle, then remove the line fittings. Remove the O-rings from the fitting connections, then replace with new ones during installation.
- Remove the left-hand side sway/stabilizer bar link.
- Remove the steering gear assembly through the left wheel well.
- Install new Teflon® O-rings into the line fittings.
- Place the gear attachment bolts in the gear housing.
- Install the steering gear assembly through the left wheel well.
- Connect and tighten the line fittings to the steering gear assembly.
- Engage the VAPS electrical connectors.
- Position the steering gear into the subframe.
- Install the tie rod ends onto the front wheel spindle tie rod.
- Install the heat shield band.
- Attach the tie rod ends onto the knuckle. Install the nuts and secure with new cotter pins.
- Attach the sway/stabilizer bar link.
- Raise the vehicle until the subframe contacts the body. Install the rear subframe attaching bolts.
- Install the gear-to-front subframe nuts, then tighten to 85-100 ft. lbs. (115-135 Nm).
- Attach the exhaust pipe to the catalytic converter.
- Install the wheels, then remove the jackstands and carefully lower the vehicle. Tighten the lug nuts to 85-105 ft. lbs. (115-142 Nm).
- From inside the vehicle, push the steering column tube boot end out of the vehicle, then install over the steering gear housing.
- Install the steering column gear input shaft coupling to the power steering gear shaft and yoke assembly. Tighten the bolt to 30-38 ft. lbs. (41-51 Nm).
- Install the inner steering column tube boot to the cowl panel.
- Install the input shaft coupling to the steering gear shaft and yoke assembly.
- Fill the power steering system with Premium Power Steering Fluid E6AZ-19582-AA or equivalent.
- Bleed the power steering system. For details, please refer to the procedure located later in this section.
- Connect the negative battery cable, then check the system for leaks and proper operation.
- If necessary, have the alignment checked by a reputable repair shop.