Power Steering System: Overhaul Ford Econoline E150

Disassembly

Note. The steering gear input shaft and seals cannot be repaired or installed separately. New gear installation may be necessary.

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1. Secure the steering gear in a vise with the indexing flat pointed down. Use protective caps on the vise jaws.
2. Rotate the power steering gear input shaft and control from stop-to-stop and then center the gear.
3. Remove the steering gear sector shaft housing cover bolts.
4. Tap on the lower end of the steering gear sector shaft. CAUTION: If there is evidence of damage or wear to the steering gear sector shaft, you must install a new steering gear assembly.
5. Remove the steering gear sector shaft.
6. Remove the locking nut from the steering gear sector shaft adjustment screw.
7. Remove the sector shaft housing cover. Hold the steering gear sector shaft. Turn the housing cover counterclockwise.
8. Remove the valve housing bolts and the identification tag.
9. Remove the valve housing and piston assembly.
10. Remove and discard the gasket.
11. Remove the ball bearings. Remove the bolts. Remove the steering gear ball return guide clamp. Remove the steering gear ball return guide. Rotate the piston over a container to collect the 28 steering gear worm balls.
12. Remove the input shaft valve and housing assembly from the piston.
13. Remove and discard the seal.
14. Place the valve housing in the holding fixture special tool and loosen the setscrew.
15. Using the special tool, remove the race nut.
16. Remove the power steering gear input shaft and control from the valve housing.
17. Rotate the valve housing with the holding fixture.
18. Use the puller to remove the power steering gear input shaft seal dust seal.
19. Remove the input shaft snap ring.
20. Rotate the valve housing with the holding fixture, and using the special tool, remove the bearing and power steering gear input shaft seal.
21. Remove the valve housing from the holding fixture.
22. Install the steering gear housing in the holding fixture and remove the steering gear sector shaft dust seal from the sector shaft seal bore.
23. Remove the spacer. Remove the snap ring. Remove the spacer.
24. Using the special tool, remove the sector shaft seal.

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1. Lubricate the sector shaft seal bore. Use multi-purpose grease.
2. Using the special tool, install the sector shaft seal. Lubricate the sector shaft seal, using multi-purpose grease.
3. Install the spacer.
4. Install the snap ring.
5. Using the special tool, install the sector shaft dust seal. Lubricate the steering gear sector shaft dust seal using multi-purpose grease.
6. Remove the steering gear housing from the holding fixture.
7. Position the input shaft bearing in the valve housing and use the special tool and a press to seat the bearing.
8. Use the special tool and a press to seat the power steering gear input shaft seal.
9. Install the input shaft snap ring.
10. Using the special tool, install the power steering gear input shaft seal dust seal.
11. Mount the valve housing to the special tool.
12. Install the power steering gear input shaft and control into the valve housing.
13. Position the power steering gear race nut into the valve housing.
14. Using the special tool, tighten the race nut.
15. Install the setscrew.
16. Remove the valve housing from the holding fixture and position the piston on the worm gear.
17. Install the steering gear ball return guide on the piston.
18. Rotate the piston while holding the steering gear ball return guide and install the 28 ball bearings into the opening in the ball guide.
19. Install the steering gear ball return guide clamp. Position the steering gear ball return guide clamp. Install the bolts.
20. Install a new gasket.
21. Lubricate and install the seal on the piston. Use multi-purpose grease.
22. Install the piston assembly into the steering gear housing.
23. Rotate the teeth so they are on the same plane as the steering gear sector shaft.
24. Loosely install the valve housing bolts and the identification tag, if so equipped.
25. Lubricate the O-ring on the sector shaft housing cover. Use multi-purpose grease.
26. Rotate the housing clockwise and install the sector shaft into the sector shaft housing.
27. Install the sector shaft lock nut.
28. Install the sector shaft and housing assembly.
29. Tighten the bolts.
30. Tighten the valve housing bolts.