Ford Windstar 1999-2003

Removal & Installation

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  1. Remove or disconnect the following:

    Front wheels
     
    Tie rod end cotter pins and castle nuts
     
    Tie rod ends from the knuckles
     
    Front stabilizer bar
     

  2.  
  3. Position the dash opening weather seal for the steering column out of the way.
  4.  
  5. Remove or disconnect the following:
    NOTE
    Use wire to support exhaust components unless you are removing them completely.



    Pinch bolt retaining the steering column intermediate shaft coupling
     
    Steering gear retaining nuts/bolts
     
    Rear subframe bolts
     

  6.  
  7. Support the exhaust system flex tube and remove the flex tube-to-dual converter Y-pipe attachment.
  8.  
  9. Lower the vehicle slightly until the rear subframe separates from the body approximately 4 inches (10cm).
  10.  
  11. Remove the heat shield band and fold the heat shield down.
  12.  
  13. Rotate the rack and pinion assembly to clear the bolts from the front subframe, and pull toward the driver-s side of the vehicle.
  14.  
  15. Place a drain pan under the vehicle and disconnect the power steering lines.
  16.  
  17. Remove the rack and pinion assembly through the driver-s side of the vehicle.

    Click image to see an enlarged view

    Fig. Exploded view of the rack and pinion steering gear mounting on the front subframe of the vehicle

  18.  

To install:

  1. Install new Teflon® O-rings on the power steering line fittings.
  2.  
  3. Place the rack and pinion retaining bolts in the gear housing.
  4.  
  5. Install or connect the following:

    Rack and pinion assembly through the driver-s side of the vehicle
     
    Power steering lines on the rack and pinion assembly
     
    Rack and pinion assembly on the subframe
     
    Strap on the heat shield
     
    Tie rod ends to the knuckles. Tighten the castle nuts and install the cotter pins.
     
    Stabilizer bar
     
    Rack and pinion assembly retaining bolts, and tighten them to 85-99 ft. lbs. (115-135 Nm).
     

  6.  
  7. Raise the vehicle until the subframe contacts the body.
  8.  
  9. Install or connect the following:

    Rear subframe retaining bolts, and tighten them to 83-112 ft. lbs. (113-153 Nm).
     
    Exhaust system flex tube-to-dual converter Y-pipe
     
    Front wheels
     

  10.  
  11. Using a new pinch bolt, install the steering column intermediate shaft coupling on the rack input shaft. Tighten the pinch bolt to 25-33 ft. lbs. (34-46 Nm).
  12.  
  13. Position the steering column opening weather seal over the steering gear housing.
  14.  
  15. Lower the vehicle.
  16.  
  17. Fill the power steering oil reservoir.
  18.  
  19. Start the vehicle and check for leaks.
  20.  
  21. Check for proper wheel alignment and steering wheel position.
  22.  

 
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