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


Removal
1 Disconnect the battery negative (earth) lead (refer to Chapter 5, Section 1).

2 Working inside the vehicle, unscrew the clamp plate bolt securing the steering column shaft to the flexible coupling. Swivel the clamp plate around, and disengage it from the flexible coupling stub.

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

Remove both wheels.

4 On manual transmission models, disconnect the gearchange linkage and support rods from the transmission, as described in Chapter 7, Part A.

5 Remove the exhaust downpipe complete, as described in Chapter 4.

6 Remove the cover from under the radiator by unscrewing the screws and releasing the clips.

7 Support the radiator in its raised position, by inserting split pins through the small holes in the radiator mounting extensions which protrude through the upper mountings (see illustration).

31.7 Method of supporting the radiator in its raised position
31.7 Method of supporting the radiator in its raised position

1 Radiator upper mounting extension 2 Small hole
3 Pin or split pin inserted through hole

8 Unbolt and remove the radiator lower mounting brackets.

9 Where applicable, unscrew the bolts securing the air conditioning accumulator to the subframe.

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

11 Unscrew the front engine mounting-tocylinder block bolts, and also the throughbolt.

12 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.

13 Working on each side in turn, unscrew the mounting nuts, and remove the anti-roll bar links from the front suspension struts. Note that, on models fitted with ABS, the ABS sensor wiring support brackets are located beneath the nuts.

14 Working on each side in turn, note which way round the front suspension lower arm balljoint clamp bolt is fitted, then unscrew and remove it from the knuckle assembly. Lever the balljoint down from the knuckle - if it is tight, prise the joint open carefully using a large flat-bladed tool. Take care not to damage the balljoint seal during the separation procedure.

15 Support the weight of the front subframe assembly on two trolley jacks (or two scissor jacks).

16 Unscrew and remove the subframe mounting bolts, then lower the subframe sufficiently to gain access to the power steering fluid pipes on top of the steering gear. Note that the front subframe mounting bolts are gold in colour - the rear ones are silver.

17 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.

18 Lower the subframe, together with the power steering gear, to the ground.

19 Unscrew the mounting bolts and remove the power steering gear from the subframe.

20 Using a suitable Allen key, unscrew the clamp bolt securing the flexible coupling to the pinion shaft on the steering gear, and withdraw the coupling.

21 Refer to Section 30, paragraph 8 for details of renewing the Teflon rings.

Refitting
22 Refit the flexible coupling to the pinion shaft on the steering gear, then insert and tighten the clamp bolt using an Allen key.

23 Locate the power steering gear on the subframe, then insert the mounting bolts and tighten to the specified torque.

24 Raise the subframe until it is possible to refit the fluid lines. Tighten the union nuts and clamps.

25 Raise the subframe, making sure that the alignment holes are in line with the holes in the underbody. At the same time, make sure that the flexible coupling locates correctly on the steering column. Ford technicians use a special tool to ensure that the subframe is correctly aligned - refer to Chapter 2 for more details of the alignment procedure. With the subframe aligned, insert and tighten the mounting bolts to the specified torque. Note that the front mounting bolts are gold in colour - the rear bolts are silver.

26 Working on each side in turn, refit the front suspension lower arm balljoint to the knuckle assembly, and insert the clamp bolt with its head facing forwards. Refit the nut and tighten to the specified torque.

27 Working on each side in turn, refit the anti-roll bar links and tighten the mounting nuts to the specified torque. On models fitted with ABS, don’t forget to locate the wheel sensor wiring support brackets beneath the nuts.

28 Refit the track rod end balljoints to the steering knuckles, and tighten the nuts to the specified torque. Check if the split pin holes are aligned, and 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.

29 Refit and tighten the engine front mounting bolts.

30 Refit the engine rear mounting and tighten the bolts.

31 Where applicable, insert and tighten the air conditioning accumulator bolts.

32 Refit the radiator lower mounting brackets and tighten the bolts.

33 Remove the split pins supporting the radiator in its raised position.

34 Refit the cover under the radiator.

35 Refit the exhaust downpipe as described in Chapter 4.

36 On manual transmission models, reconnect the gearchange linkage and support rods.

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

38 Working inside the vehicle, reconnect the steering column clamp plate, then insert the bolt and tighten to the specified torque.

39 Reconnect the battery negative lead.

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

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


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