Section 11-02B: Steering Gear, Power, Ford
1996 F-150, F-250, F-350, F-Super Duty and Bronco Workshop Manual
DISASSEMBLY AND ASSEMBLY

Input Shaft and Valve Assembly

SPECIAL SERVICE TOOL(S) REQUIRED
DescriptionTool Number
Adjuster and Lock Nut WrenchT66P-3553-B
Bench Mounted Holding FixtureT57L-500-B
PullerT58L-101-B
Impact Slide HammerT59L-100-B
Impact Shaft Bearing/Seal ToolT65P-3524-A1,
A2, A3

Disassembly

  1. Remove the steering gear from the vehicle.

  1. Drain all the remaining fluid from the steering gear into a suitable container.

  1. Mount the steering gear vertically in a soft-jawed vice with the power steering gear input shaft and control (3D517) pointing up.

  1. Remove the four bolts retaining the valve housing to the steering gear.

  1. Turn the loosened valve housing clockwise until there is approximately 34mm (1.5 inch) between the valve housing and the steering gear housing (3548).

  1. Insert two temporary bolts, approximately 62mm in length, through the valve housing to the steering gear keeping the 34mm (1.5-inch) clearance between the valve housing and the steering gear.

  1. Remove the lock nut retaining setscrew from the valve housing.

  1. Using Adjuster and Lock Nut Wrench T66P-3553-B remove the steering gear worm thrust bearing locknut (3707).

  1. Remove the previously installed bolts and then remove the valve housing.

  1. Mount the valve housing into Bench Mounted Holding Fixture T57L-500-B.

  1. Using Puller T58L-101-B and Impact Slide Hammer T59L-100-B, remove the dust seal from the valve housing.

  1. Remove the snap ring from the valve housing.

  1. Turn the bench mounted holding fixture to invert the valve housing.

  1. Insert Impact Shaft Bearing/Seal Tool T65P-3524-A2 and T65P-3524-A3 into the valve body assembly opposite the oil seal end, and gently tap the bearing and the pressure seal out of the housing.

Assembly

  1. Inspect steering gear worm ball (3647) and power steering gear input shaft and control for any damage. Replace components as required.

  1. Coat the steering gear worm ball kit and seal surface of the housing with petroleum jelly or equivalent.

  1. Install the steering gear worm ball kit with the metal side covering, facing the rollers outward. Seat the steering gear worm ball kit in the valve housing using Input Shaft Bearing/Seal Tool T65P-3524-A1. Be sure steering gear worm ball kit rotates freely.

  1. Dip a new oil seal in Standard Transmission Lubricant (SAE 80W) D8DZ-19C547-A or equivalent meeting Ford specification ESP-M2C83-C and place it into the housing with the metal side facing outward. Drive the seal into the housing until the outer edge does not quite clear the snap ring groove.

  1. Insert the snap ring in the housing until it is fully seated in the groove.

  1. Place the new dust seal in the housing with the dished side facing out. Using Tool T65P-3524-A3, drive Dust Seal T64P-3524-A1 into place.

  1. NOTE: When the valve housing is reinstalled, the seal will be located just past the undercut in the power steering gear input shaft and control.

    Pack the area between the two seals with Multi-Purpose Grease D0AZ-19584-AA or equivalent meeting Ford specification ESB-M1C93-A.

  1. Inspect valve housing O-ring for damage. Replace if required.

  1. Install the valve housing on the power steering gear input shaft and control. Install the two 62mm temporary bolts keeping 34mm (1.5 inch) between the valve housing and the steering gear housing as done during Step 6 of the disassembly process.

  1. Install the power steering gear race nut (3D627) and tighten to 75-122 Nm (55-90 lb-ft). Install the lock nut setscrew.

  1. Remove the 62mm temporary bolts and position the valve housing onto the steering gear housing. Install the valve housing retaining bolts and tighten to 40-60 Nm (30-44 lb-ft).

  1. Remove the steering gear from the soft-jawed vise and install it into the vehicle.