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Steering Gear: Reassembly

  1. Install a new "O" ring on spool valve. Apply Long Life Lubricant (C1AZ-19590-BA) to pivot lever hole in spool valve and to pivot lever hole in valve body. Apply ATF to rest of spool valve. Install spool valve. Apply Long Life Lubricant to pivot lever/collar and to bushing.
  2. Install pivot lever into spool valve housing. Make sure longest end of pivot lever/collar is seated in spool valve. Install end plug in spool valve housing. Apply ATF to inner guide. Push inner guide and inner rack seal into rack housing with Inner Rack Seal Remover (T87C-3504-A).
  3. Apply Long Life Lubricant to rack teeth. DO NOT  plug rack air hole with grease. Install Rack Oil Seal Protector (D83P-3504-K). Install a new rack piston seal on rack using Piston Seal Replacer (T81P-3504-L) with Pusher (T75L-3517-A2) and Sizer (T81P-3504-K).
  4. Apply ATF to rack piston and cover rack with electrical tape. Coat inside of rack housing with ATF and carefully slide rack into housing. Slide rack as far as it will go into housing. Remove rack seal protector. Install a new bushing into outer bulkhead using Pinion Cover Centering Tool T18P-3504-Y.
  5. Install a new sealing ring, oil seal and "O" rings at bulkhead end of rack housing. Lubricate all parts with ATF before installation. Wrap outer bulkhead with towel and install with pipe wrench. Stake bulkhead to rack housing with punch. Install lower bearing on pinion shaft. Install and tighten retaining nut to 29-36 ft. lbs. (40-50 N.m).
  6. Stake nut to pinion shaft. Install pinion shaft into housing with rack extending 2.70" (68.7 mm) out of housing on pinion shaft end or centered in housing. Also, notch on pinion shaft spline must be located 60 degrees from horizontal center. See Fig 1 .
    Fig 1: Installing Pinion Shaft (Capri)
    G92E00707Courtesy of FORD MOTOR CO.
  7. Grease upper pinion bearing and install in housing using Upper Pinion Seal Replacer (T78P-3504-D). Tighten pinion bearing cover to 44-79 INCH lbs. (5-9 N.m). Then loosen it 10-20 degrees. Tighten lock nut to 29-36 ft. lbs. (40-50 N.m).
  8. Using a new gasket, attach valve body to rack housing. Install yoke, spring, adjusting plug and lock nut. Tighten cover to 39-47 INCH lbs. (4.5-5.5 N.m). Loosen cover 45 degrees. Measure pinion torque using inch lb. torque wrench and Pinion Adapter (T87C-3504-C).
  9. Pinion torque should be .52-1.3 INCH lbs. (.6-1.5 N.m). If pinion torque is not within specification, loosen or tighten adjusting plug. After pinion torque is set, tighten lock nut to 29-36 ft. lbs. (40-50 N.m). Mount steering gear in soft-jawed vise and install damper ring, washer and tie rod.
  10. Tighten tie rod to 43-58 ft. lbs. (60-80 N.m). Stake tab washer in 2 places. Position damper ring in washer. Install other damper ring, washer and tie rod. Install tie rod dust boots and secure outer ends with clamps and inner sides with mechanics wire.
  11. Install tie rod ends and adjust according to index marks put on during disassembly. Wrap electrical tape around and apply grease to pinion shaft. Apply grease to lips of pinion shaft seal. Install pinion shaft seal using Pinion Bearing Replacer (T78P-3504-D).
  12. Remove electrical tape from pinion shaft. Install support brackets and rubber bushings. Install external oil lines and 2 new copper sealing rings.


  1. Install grommets and mounting brackets. Install new seal using Rack Oil Seal Replacer T81P-3504-C. Install new "O" ring using Piston Seal Replacer (T81P-3504-L) and Rack Piston Seal Sizer (T81P-3504-K). Place Short Rack Seal Replacer (T81P-3504-N) over end of rack to protect bushing.
  2. Install bushing on rack. Place Rack Seal Protector (T87P-3504-H) on rack. See Fig 1 . Install rack. Remove rack seal protector. Insert rack retaining wire through slot and into bushing hole. Install retaining wire using Outer Box Torque Adapter (T88C-3504-CH).
    Fig 1: Installing Rack Seal Protector (Festiva)
    G92F00708Courtesy of FORD MOTOR CO.
  3. Install lower pinion bearing using Pinion Bearing Replacer (T90C-3504-DH). If valve housing, steering gear, or pinion and control valve assembly have been replaced, go to step 4). If none of these components have been replaced, go to step 6).
  4. Measure valve housing, lower bearing and spacer, and steering gear housing. See Fig 2 . Use the following formula to determine proper shim thickness: T = A C - B Where "T" is the shim thickness.
    Fig 2: Determining Replacement Shim Thickness (Festiva)
    G91F03497Courtesy of FORD MOTOR CO.
  5. Having calculated required shim thickness, divide the required shim thickness by .0020" (.05 mm). This is the thickness of replacement shims. Round off to the nearest equal shim thickness.
  6. Install previously removed shim(s) into valve housing. Install new Teflon pinion seals on pinion and control valve assembly using Pinion Valve Seal Installation Set (T81P-3504-M). Install first seal (seal closest to bearing) by sliding Mandrel (T81P-3504-M1) over valve assembly to first seal groove.
  7. Push seal into groove with Pusher (T81P-3504-M2). Size the seal by sliding large end of Sizer (T81P-3504-M3) over seal. Before installing second seal, place Spacer (T81P-3504-M4) on valve assembly near splined end. Install and size using Mandrel (T81P-3504-M1) and Pusher (T81P-3504-M2).
  8. Before installing third seal, place 2 Spacers (T81P-3504-M4) on valve assembly near splined end. Install and size third seal. To install fourth seal, turn second spacer around so the small ends of each spacer are facing. Install an size fourth seal.
  9. Insert pinion and control valve assembly into valve housing, making sure it seats properly. Install New "O" ring. Install valve housing mount bolts and tighten to 15-19- ft. lbs. (21-25 N.m). Install upper pinion bearing and seal using Pinion Seal Replacer/Torque Adapter (T90C-3504-EH).
  10. Install snap ring, support yoke and spring. Install yoke plug and tighten to 86 INCH lbs. (9.8 N.m). Loosen yoke plug and install Yoke Plug Torque Gauge T90C-3504-CH over yoke plug. Tighten yoke plug to 38-48 INCH lbs. (4.4-5.4 N.m). Make scribe mark on support yoke at zero point on yoke plug torque gauge.
  11. Loosen yoke plug until 45 degree mark on yoke plug torque gauge is aligned with scribe mark on support yoke. Apply sealant to exposed threads of yoke plug. Install lock nut and tighten to 36-43 ft. lbs. (49-59 N.m). Install tie rods and tie rod lock pins. Install boots, boot wires and clips, and fluid lines.
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