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Power steering gear (all except left-hand-drive models with ABS) - removal and refitting
Suspension and steering systems / Power steering gear (all except left-hand-drive models with ABS) - removal and refitting


Removal
1 Remove the steering column flexible coupling as described in Section 29.

2 Apply the handbrake, then jack up the front of the vehicle and support it on axle stands.

Remove both front wheels.

3 Working beneath the vehicle, unbolt the rear engine mounting from the transmission and underbody.

4 Extract the split pins from the track rod end balljoint nuts, then unscrew the nuts, and detach the rods from the arms on the steering knuckles using a conventional balljoint removal tool. Take care not to damage the balljoint seals.

5 Position a suitable container beneath the steering gear, then unscrew the union nuts securing the power steering fluid supply, return, and cooler lines to the steering gear.

Identify the lines for position, then unbolt the clamps, disconnect the lines, and allow the fluid to drain into the container. Cover the apertures in the steering gear and also the ends of the fluid pipes, to prevent the ingress of dust and dirt into the hydraulic circuit.

6 Unscrew and remove the steering gear mounting bolts. The bolts are located on top of the steering gear, and are difficult to reach.

Ideally, the special U-shaped Ford spanner should be used, but it is just possible to reach them with a normal spanner (see illustration).

30.6 U-shaped Ford spanner for unscrewing the steering gear mounting bolts
30.6 U-shaped Ford spanner for unscrewing the steering gear mounting bolts

7 Withdraw the steering gear through the wheel arch.

Refitting
8 If the steering gear is being replaced with a new one, the new unit will be supplied together with union nuts already fitted. The new nuts must only be used with new feed and return lines - otherwise, they must be removed and discarded. If the original lines and union nuts are being used, the Teflon rings on the union nuts must be renewed. To do this, the rings must be expanded individually onto a fitting adaptor (see illustration), then located in the grooves of the union nuts.

30.8 Using an adaptor to fit the Teflon rings to the union nuts
30.8 Using an adaptor to fit the Teflon rings to the union nuts

1 Adaptor
2 Teflon ring
3 Union nut
4 Groove location for the Teflon ring

9 Locate the steering gear on the subframe, and insert the two mounting bolts. Tighten the bolts to the specified torque (see illustration).

Note that, if the special Ford tool is being used, the bottom of the tool must be turned anti-clockwise in order to tighten the mounting bolts.

30.9 Tightening the steering gear mounting bolts using the U-shaped spanner
30.9 Tightening the steering gear mounting bolts using the U-shaped spanner (arrowed)

10 Remove the covers from the apertures on the steering gear, then reconnect the fluid lines and tighten the union nuts to the specified torque. Refit the clamps and tighten the bolts.

11 Refit the track rod end balljoints to the steering knuckles, and tighten the nuts to the specified torque. Check that the split pin holes are aligned; if necessary, turn the nuts to the nearest alignment, making sure that the torque wrench setting is still within the specified range. Insert new split pins, and bend them back to secure.

12 Refit the rear engine mounting to the transmission and underbody, and tighten the bolts to the specified torque.

13 Refit the front wheels, and lower the vehicle to the ground.

14 Refit the steering column flexible coupling with reference to Section 29.

15 Bleed the power steering hydraulic system as described in Section 33.

16 Have the front wheel alignment checked, and if necessary adjusted, at the earliest opportunity (refer to Section 36).


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