Steering System - Integral Power Ford Econoline E350

DESCRIPTION

Note. Unless otherwise specified, references to Pickup include the F350 Super Duty commercial chassis.

Integral power steering unit consists of a rotary hydraulic control valve housing, input shaft/worm gear/valve sleeve assembly, sector shaft, and 1-piece piston containing 27-29 recirculating balls. The 1-piece piston's teeth are meshed to sector shaft teeth. Sector shaft is connected to Pitman arm. Rotary hydraulic control valve assembly contains upper input shaft/valve sleeve, sleeve Teflon seals, and internal torsion bar. The input shaft/control valve sleeve is retained inside control valve housing by bearing and lock nut. Hydraulic action is generated by relative rotary motion between input shaft/control valve sleeve and worm/piston assembly. (Scheme 1)and (Scheme 7).

Scheme 1

Scheme 2

The C-II power steering pump is used on all models except Van. The C-II pump is a belt-driven, slipper-type integral pump with a fiberglass/nylon reservoir. Reservoir is attached to rear of pump housing plate. (Scheme 2)

The C-II pump high-pressure hose is attached to pump using a swivel type fitting with "O" ring seal. This type fitting allows for hose movement without stressing line or fitting. Pump low pressure hose is slip-on design with hose clamp. Pump's high pressure hose fitting and low pressure hose pipe are located below filler neck at outboard side of reservoir. A pump identification tag with basic model number is attached to reservoir. (Scheme 2)

The Saginaw power steering pump is used on Van. Pump is a constant displacement vane-type pump. The reservoir is "O" ring sealed onto the pump housing. All integral pump moving parts are submerged in fluid. The fluid filler opening is on top of reservoir, unless engine type requires alternate remote reservoir. Pump reservoir cap is sealed when using remote reservoir.

Rectangular pump vanes are mounted into rotor and cam, and are driven by main pump shaft. Vanes move fluid from reservoir into cam ring. Fluid is pressurized by vanes in cam ring, then forced into cavities of thrust plate and through flow control valve. The flow control valve, regulates pressurized fluid to the steering gear unit. (Scheme 3)

TROUBLE SHOOTING

Refer to TROUBLE SHOOTING - BASIC PROCEDURES article in the GENERAL TROUBLE SHOOTING section.

FLUID TYPE

Use Ford Premium Power Steering Fluid (E6AZ-19582-AA) or use Type "F" ATF fluid.

FLUID LEVEL CHECK

Fluid level may be checked when fluid is either hot or cold. If fluid is cold, below 75°F (24°C), check fluid level using the COLD full mark on dipstick. If fluid is hot, about 177°F (77°C), check fluid level using the HOT full mark on dipstick. If fluid is low, add small amount of fluid through dipstick opening and recheck fluid level. DO NOT overfill. On some van applications, check remote reservoir for proper fluid level. Remote reservoir has "full" and "low" lines on side of reservoir.

HYDRAULIC SYSTEM BLEEDING

1. Raise front wheels off surface and support vehicle. Fill reservoir to specified level. Run engine until power steering fluid reaches normal operating temperature, about 165-175°F (74-79°C). Recheck fluid level in reservoir and top off as necessary. With engine running, eliminate trapped air in system by turning steering wheel from lock-to-lock until fluid level no longer decreases and no bubbles exist in reservoir.
2. DO NOT hold steering wheel against lock (in far left or far right position). This action will create extremely high pressure and damage pump. Recheck fluid level in reservoir and top off as necessary.

Scheme 3

BELT ADJUSTMENT

Note. For proper serpentine belt routing, see ADJUSTMENTS article in the ENGINE PERFORMANCE section.

BELT ADJUSTMENT

STEERING GEAR MESHLOAD

1. Reference mark pitman arm to sector shaft. Using Pitman Arm Puller (T64P-3590-F), remove pitman arm from sector shaft. Disconnect fluid return line at pump reservoir. Cap reservoir return line pipe. Place end of return line in suitable container.
2. Turn steering wheel in both directions several times to drain fluid. DO NOT reuse this fluid. Remove horn button from steering wheel to access steering wheel nut. Turn steering wheel until positioned 45 degrees from left or right steering stop.
3. Using an INCH lb. torque wrench on steering wheel nut, record torque required to turn steering shaft 1/8 turn toward top center from present 45 degrees position. (This is torque required to "start" steering wheel to move.)
4. Turn steering gear to center position. (This is steering wheel normal center position, half way between lock-to-lock.) Using an INCH lb. torque wrench on steering wheel nut, record torque required to move steering wheel and shaft, back and forth across top center position. Compare the two readings.
5. If vehicle is new (less than 5000 miles), center reading should be 12-24 INCH lbs. (1.4-2.7 N.m). Adjust as required, go to step 6). If vehicle has more than 5000 miles or sector shaft has been replaced, compare over center torque reading with torque recorded in step 3). If centering torque is greater than or less than recorded "starting" torque by 10 INCH lbs. (1.1 N.m), adjust to 9-13 INCH lbs. (1.0-1.5 N.m). To adjust, go to next step.
6. To adjust meshload, loosen sector shaft lock nut, turn sector shaft adjustment screw until proper torque reading across center position is obtained, Repeat Steps 3) -5). (Scheme 1) Tighten lock nut while holding adjusting screw in place.
7. Install horn button/pad. Attach pitman arm nut and tighten to specifications. See «TORQUE SPECIFICATIONS»(/ford/econoline-e350/1985-1999/remont/manual-power-steering/#steering-system-integral-power__torque-specifications). Reconnect pump hose. Add fluid and bleed system. See «HYDRAULIC SYSTEM BLEEDING»(/ford/econoline-e350/1985-1999/remont/manual-power-steering/#steering-system-integral-power__hydraulic-system-bleeding) under LUBRICATION.

PRESSURE TEST

Note. For testing, use Power Steering Analyzer (D79L-33610-A) with flow meter.

Preparation

1. Ensure belt tension correct. Disconnect power steering pump high pressure hose. Keep hose end raised to prevent fluid loss. Connect pressure hose of analyzer gauge to power steering pump fitting. Connect power steering pump high pressure hose to analyzer gauge hose at valve side of tester.
2. Open valve. Check fluid level and add fluid as required. Run engine until fluid reaches normal operating temperature of 165-175°F (74-79°C).

1. With engine idling, record flow reading on analyzer gauge. If minimum flow is less than 1.6 gallon per minute (6.1L per minute) on Explorer and Ranger, OR less than 2 gallons per minute (7.6L per minute) on Bronco, Pickup and Van, pump may require repair or replacement. Continue test.
2. At idle, if pressure is greater than 150 psi (11 kg/cm 2 ), check hoses for restrictions. Replace as required. Partially close analyzer gate valve to build up pressure to 740 psi (52 kg/cm 2 ) for C-II pump or 620 psi (44 kg/cm 2 ) on Saginaw pump (Van).
3. If flow drops below specification, disassemble pump and replace cam pack assembly. If pressure plates are cracked or worn, replace.
4. DO NOT close analyzer gate valve for more than 5 seconds. Completely close and partially open gate valve 3 times. Record highest reading each time. If pressure is higher or lower than specified, repair or replace flow control valve or pump. Refer to appropriate PRESSURE TEST SPECIFICATIONS table. PRESSURE TEST SPECIFICATIONS Application Idle Pressure (1) psi (kg/cm 2 ) Relief Pressure psi (kg/cm 2 ) Ford C-II Pump Model HBC-KC 740 (52) 1050-1230 (74-86) (1) Engine idle RPM must be set to engine decal specification to obtain idle pressure. PRESSURE TEST SPECIFICATIONS Application Idle Pressure (1) psi (kg/cm 2 ) Relief Pressure psi (kg/cm 2 ) Ford C-II Pump 740 (52) 1300-1480 (91-104) (1) Engine idle RPM must be set to engine decal specification to obtain idle pressure. PRESSURE TEST SPECIFICATIONS Application Idle Pressure (1) psi (kg/cm 2 ) Relief Pressure psi (kg/cm 2 ) Saginaw Pump Model HBA-HA/HB 620 (44) 1250-1450 (88-102) Ford C-II Pump Model HBC-JX 740 (52) 1300-1530 (91-108) Ford C-II Pump Model HBC-JY 740 (52) 1350-1530 (95-108) (1) Engine idle RPM must be set to engine decal specification to obtain idle pressure.
5. Set engine speed at 1500 RPM. Record flow. If flow varies more than 1 gallon (3.8L) per minute from pressure measured in step 1), flow control valve in pump must be repaired or replaced.
6. Turn steering wheel to left and right stops, holding at each stop for 3 seconds. Pressure should be nearly the same as maximum relief pressure. See appropriate PRESSURE TEST SPECIFICATIONS table. Flow should drop below .5 gallon (1.9L) per minute.
7. If pressure and flow are not as specified, steering gear is leaking internally. Remove steering gear unit. Remove flow control valve. Repair or replace damaged parts. Check control valve seals for damage. See «STEERING GEAR UNIT»(/ford/econoline-e350/1985-1999/remont/manual-power-steering/#steering-system-integral-power) under OVERHAUL.
8. If pressure and flow are good, turn steering wheel slightly in both directions and release quickly while watching pressure gauge. Needle should move from normal backpressure reading when steering wheel is turned, and needle should snap back as wheel is released. If gauge reacts slowly, or sticks, rotary valve sleeve assembly in steering gear is sticking. Repair or replace rotary valve sleeve assembly.
9. Check fluid for signs of contamination. If system is severely contaminated, both hoses, control valve, and pump must be disassembled and cleaned. After reassembly, if problem still exists, check ball joints, linkage and other front suspension members.

ROTARY VALVE CENTERING

Note. Power steering fluid must be at normal operating temperature and at correct level.

1. Install Power Steering Analyzer (D79L-33610-A) or equivalent (i.e. 0-2000 psi pressure gauge and valve assembly) between power steering pump and high pressure line. ENSURE analyzer gauge gate valve is completely OPEN. Remove horn button/pad from steering wheel.
2. Attach an INCH lb. torque wrench to steering wheel nut. Center steering wheel. Set engine idle to 1000 RPM. Using torque wrench, rotate steering wheel to either side of center to obtain gauge reading of 250 psi (17.5 kg/cm 2 ) in each direction.
3. Torque wrench reading should be equal in both directions when gauge is at 250 psi (17.5 kg/cm 2 ). If difference between torque readings exceeds 6 INCH lbs. (.68 N.m), remove steering gear unit. Replace worm shaft/valve sleeve Teflon sealing rings, and replace control valve housing assembly. (Scheme 7)

Removal

1. Disconnect fluid return hose at reservoir and drain fluid into suitable container. Remove high pressure hose and power steering pressure switch (if equipped) from pump and drain fluid into container. Depending on vehicle, to remove drive belt loosen either belt tensioner, alternator, or power steering pump adjustment bracket bolts. Remove steering pump adjustment bracket bolts (if equipped ).
2. On most models, pump pulley must be removed before pump can be removed from support bracket on engine. Remove pulley from pump using Pulley Remover (T69L-10300-B). (Scheme 4) DO NOT use conventional type puller to remove pulley, pulley damage will result.
3. Remove pump, and adjustment bracket (if equipped) from support bracket. On some models, air conditioning compressor must be removed from support bracket to access power steering pump mounting bolts.

Scheme 4

Installation

1. Install pump assembly to support bracket. Tighten bolts to specification. If equipped, install adjustment bracket-to-support bracket and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline-e350/1985-1999/remont/manual-power-steering/#steering-system-integral-power__torque-specifications).
2. Install pulley to pump shaft using Pulley Installer (T65P-3A733-C). (Scheme 4) Pulley must be within.010" (.25 mm) of end of pump shaft to align with other pulleys for proper belt operation.
3. Apply lifting pressure to tensioner pulley and install belt on pump pulley. Ensure proper belt routing. See «SPECIFICATIONS»(/ford/econoline-e350/1985-1999/remont/specifications/#engine-controls-specifications) article in the ENGINE PERFORMANCE section. If equipped with adjustment bracket, adjust belt and tighten pump adjustment bracket bolts to specification.
4. Install hoses to pump. Tighten pressure hose fitting to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline-e350/1985-1999/remont/manual-power-steering/#steering-system-integral-power__torque-specifications). Fill reservoir with new fluid. Start engine and let idle. Turn wheel from stop-to-stop to bleed air from system. Recheck reservoir and refill as necessary.

1. Remove pump from engine. See «POWER STEERING PUMP R & I»(/ford/econoline-e350/1985-1999/remont/manual-power-steering/#steering-system-integral-power). Drain fluid from reservoir. If pulley was not previously removed, remove pulley using Pulley Remover (T69L-10300-B). (Scheme 4) DO NOT use conventional type puller to remove pulley, pulley damage will result.
2. Insert sharp, strong tool between rotor shaft seal and pump housing. DO NOT insert tool between shaft and seal, damage to shaft surface will result in fluid leak. Pry out seal from housing and remove seal from shaft.

1. Install new seal onto shaft with metal backing facing outward (toward pulley end of shaft). Install seal using appropriate seal installer. Tap seal installer lightly with hammer until seal is properly seated flush with housing.
2. If required, install pump assembly to support bracket before installing pulley to pump shaft. Also if required, install adjustment bracket-to-support bracket and tighten all bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline-e350/1985-1999/remont/manual-power-steering/#steering-system-integral-power__torque-specifications).
3. Install pulley to pump shaft using Pulley Installer (T65P-3A733-C). (Scheme 4) Pulley must be within.010" (.25 mm) of end of pump shaft to align with other pulleys for proper belt operation. To complete installation, see «POWER STEERING PUMP R & I»(/ford/econoline-e350/1985-1999/remont/manual-power-steering/#steering-system-integral-power).

1. Place drain pan under vehicle, under steering gear unit. Disconnect hydraulic lines at power steering gear control valve. Quickly cap lines and gear unit ports to prevent contamination and loss of fluid. Remove splash shield from steering shaft-to-gear unit flex coupling. Remove coupling clamp bolt. Raise and support vehicle.
2. Mark relation of pitman arm to sector shaft for reassembly reference. Remove pitman arm nut and washer. Using Pitman Arm Puller (T64P-3590-F), remove pitman arm from sector shaft.
3. Remove steering gear-to-frame attaching bolts. Work steering gear free of flex coupling splines and remove steering gear from vehicle. Use care not to damage flex coupling material. It may be necessary to spread coupling clamp slightly to remove gear unit input shaft.

1. Center steering wheel. If equipped, install lower splash shield over upper gear unit input shaft. Center steering gear input shaft with indexing flat facing down. Slide steering gear input shaft into position in flex coupling. Install steering gear-to-frame and tighten bolts to 50-62 ft. lbs. (68-84 N.m). Install coupling clamp bolt and tighten to 26-34 ft. lbs. (35-46 N.m).
2. With wheels in straight-ahead position and/or aligning reference marks, install pitman arm on sector shaft. Install washer and nut on pitman arm. Tighten to 170-228 ft. lbs. (230-309 N.m). Install steering shaft splash shield to flex coupling. Connect and tighten hydraulic lines to steering gear control valve housing. Tighten hose fittings to 20-30 ft. lbs. (27-41 N.m).
3. Fill reservoir to proper level. Disconnect primary and secondary coil wires and isolate them from ground. Crank engine while turning steering wheel left to right to distribute fluid. Recheck fluid level, add if needed. Check for fluid leaks. If no leaks exist, reconnect primary and secondary coil wires. Start vehicle and bleed system. See «HYDRAULIC SYSTEM BLEEDING»(/ford/econoline-e350/1985-1999/remont/manual-power-steering/#steering-system-integral-power__hydraulic-system-bleeding) under LUBRICATION.

POWER STEERING PUMP

Note. Before disassembly, drain fluid from pump and thoroughly clean exterior of pump with solvent. Seals are not reusable after being washed by solvent.

Scheme 5

Scheme 6

1. Remove outlet fitting, seals, flow control valve, and spring. Lift reservoir from pump housing. (Scheme 2) Place "C" Clamp Tool (T74P-3044-A1) in vise. Install Lower Support Plate (T78P-3733-A2) over pump rotor shaft.
2. Place pump assembly into "C" clamp hole with rotor shaft facing down. (Scheme 5) Install Upper Compressor Plate (T78P-3733-A1) into "C" clamp and snug clamp/plate to valve body.
3. Tighten "C" clamp until slight bottoming of valve cover is felt. Insert small drift through hole in side of pump housing plate. Push valve cover retaining ring inward and remove ring. (Scheme 6)
4. Loosen "C" clamp and remove pump. Remove valve cover from pump assembly. Remove "O" ring seal from valve cover. Slowly push on pulley end of rotor shaft to remove rotor shaft, rotor and slippers, upper plate, and cam insert and 2 dowel pins from housing. Be careful not to push rotor completely out of cam causing slippers and springs to fall or jump out. (Scheme 2)
5. By tapping housing on flat surface, remove lower plate and disc spring. Discard all "O" ring seals. Using a screwdriver, remove rotor shaft seal and seal retainer. Use care not to gouge or scratch pump housing seal surface.

Reassembly

1. Place rotor onto rotor shaft splines, with rotor's large counterbore facing upward. Install retaining ring in rotor shaft groove. Place insert cam over rotor with recessed flat facing toward reservoir.
2. With rotor held half way out of cam, insert spring into rotor spring pocket. Use a slipper to compress spring. Install slipper with narrow groove facing cam. Slippers must be installed with narrow groove rail spacing facing cam, otherwise pump will not function.
3. Hold cam stationary. Turn rotor one space at a time and install all 10 rotor springs and slippers. Ensure springs and slippers do not fall out when turning rotor.
4. Using a plastic mallet and Seal Driver (T78P-3733-A3), install a new rotor shaft seal to housing by driving seal and then seal retainer into bore until bottomed. Turn pump housing over and position pump housing plate on a flat surface with pulley/seal side down. (Scheme 2)
5. Insert 2 dowel pins and disc spring (dished surface upward) into housing plate. Lubricate lower pressure plate "O" ring seals with power steering fluid. Install seals to lower pressure plate.
6. Insert lower pressure plate with "O" ring seals toward front of pump, into bottom of pump housing plate and over dowel pins. Place pump housing plate assembly into "C" clamp using lower support plate on pump rotor shaft to protect new seal. (Scheme 5) Place Driver (T78P-3733-A3) in center rotor shaft hole.
7. Tighten "C" clamp to press driver and lower plate lightly until it is "felt" to be bottomed in pump plate housing. This operation will seat lower pressure plate "O" ring. Install cam/rotor assembly (containing cam, rotor, slippers, and rotor shaft), into pump housing plate over dowel pins. NOTE: When installing cam/rotor assembly, stepped holes must be used for dowel pins. Recessed notch in cam insert must face reservoir and be about 180° opposite square pump mounting boss.
8. Place upper pressure plate over dowel pins. Side of plate with square recessed notch must face reservoir end and be positioned 180° opposite the pump's square mounting boss. Place new "O" ring seal on valve cover. Lubricate with power steering fluid. NOTE: Ensure plastic baffle is securely in place in valve cover. If not, apply petroleum jelly to baffle. Install baffle.
9. Place valve cover over dowel pins. Ensure valve cover outlet fitting hole is directly in line with square mounting boss of pump housing plate.
10. Place entire pump housing assembly in "C" clamp tool. Install upper compressor plate to valve cover and tighten "C" clamp to compress valve cover into pump housing plate, until retaining ring groove is exposed in pump housing plate.
11. Install valve cover retaining ring with ends near access hole in pump housing plate. (Scheme 6) Remove pump assembly from "C" clamp tool. Place new large "O" ring seal on outside of pump housing plate. Lubricate "O" ring seal with power steering fluid. Install power steering reservoir to pump housing, aligning outlet fitting hole in reservoir with threaded fitting hole in valve cover. (Scheme 2)
12. Install flow control spring and flow control valve into valve cover. Place new "O" ring seals on outlet fitting. Lubricate seals with power steering fluid.
13. Install pump outlet fitting into valve cover. Tighten fitting to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline-e350/1985-1999/remont/manual-power-steering/#steering-system-integral-power__torque-specifications).

Disassembly (Saginaw Type)

1. Drain pump reservoir. Clean exterior of unit with solvent. Remove mounting bracket(s). If pulley was not previously removed, remove pulley using Pulley Remover (T69L-10300-B). (Scheme 4) DO NOT use conventional type puller to remove pulley, pulley damage will result.
2. Turn pump over to point pulley shaft down. Clamp square boss of pump shaft housing in a soft jawed vise. Remove high pressure line union fitting and "O" ring seal from rear of reservoir. Remove reservoir mounting bolts and studs. (Scheme 3)
3. Using plastic hammer, tap against filler tube and around reservoir beaded edge to loosen and remove reservoir from pump body. Remove and discard large "O" ring seal.
4. Using 1/8" punch, tap end plate retaining ring around until end of ring is near hole in pump body. (Scheme 6) Inserting punch into hole, disengage ring from groove in pump bore. Using a screwdriver, pry ring from body.
5. Tap end plate with a soft-faced hammer to loosen. Spring tension will push plate up. Remove pressure plate spring. Remove pump from vise. (Scheme 3)
6. Remove end plate "O" ring. Invert pump and place on flat surface. Using soft-faced hammer, tap end of drive shaft to loosen and remove pressure plate, cam ring and rotor vanes. Remove rotor and shaft assembly by pushing end of shaft through pump housing while lifting pump housing.
7. Lift pump housing off rotor and shaft assembly. Flow control valve and spring should slide out of bore. Clamp rotor drive shaft in soft-jawed vise, with rotor and thrust plate facing up. Pry rotor retaining ring from shaft. Use care not to nick shaft or rotor. Slide rotor and thrust plate off shaft. Remove shaft from vise.
8. Remove both dowel pins from housing. Remove pressure plate "O" ring from pump housing bore and discard. Using a screwdriver, pry drive shaft oil seal from pump housing.

Cleaning & Inspection

1. Clean all pump components in clean solvent. Blow dry. Inspect flow control valve assembly for wear, scoring, burrs or other damage. Inspect seal bore for burrs, nicks, or score marks that would allow oil to by-pass outer seal surface.
2. Check all machined surfaces of body for scratches or burrs which might allow leaks. Check "O" ring mating surfaces. Inspect pump housing drive shaft bushing for excessive wear.
3. If replacement is required, replace pump and bushing as an assembly. Inspect end plate "O" ring mating surface for nicks and burrs. Polish with oil stone (if required).
4. Inspect rotor ring for roughness or irregularities. Use oil stone to correct minor irregularities. Replace ring if outside cam surface is worn or scored.
5. Check thrust plate and pressure plate for scoring and wear. To remove light scoring, lap with crocus cloth until surface is smooth and flat. Clean thoroughly. Check that vanes slide freely but fit snugly into slots. Replace as required.
6. If vanes are loose in rotor slots, replace rotor and/or vanes. Scoring on rotor may be removed with crocus cloth. Clean all components thoroughly.

1. Lubricate all "O" rings, seals and seal surfaces with power steering fluid, or petroleum jelly. With pump on flat surface, drive new shaft seal in until it bottoms on bore shoulder.
2. Clamp pump housing in vise with shaft pointing down. Install pressure plate "O" ring in housing bore and into third groove from end of housing. Remove housing from vise.
3. Clamp shaft, splined end up, in soft-jawed vise. Install thrust plate with smooth, ported side upward, onto shaft. Slide rotor over shaft splines with counter bore down toward thrust plate. Install new rotor retaining ring to shaft. Ensure ring is seated in groove.
4. Install 2 dowel pins into holes in pump housing bore. Lubricate shaft with power steering fluid. Insert drive shaft, rotor, and thrust plate assembly into pump bore. Align thrust plate locating holes with dowel pins. Ensure thrust plate slides properly on dowel pins.
5. Slide cam ring over rotor and onto dowel pins, with arrow on cam ring facing toward rear of housing. Install vanes in rotor slots with rounded edge of vane facing out towards cam ring inner surface. Vanes should slide freely in rotor.
6. Lubricate pressure plate with power steering fluid. Position pressure plate on dowel pins with circular spring depression facing rear of housing. Narrow slots in plate should engage dowel pins. Using a 1 1/4" socket in groove of pressure plate, press down on socket with both thumbs to seat plate assembly over "O" ring in pump housing bore. Lubricate end plate "O" ring with power steering fluid and install in second groove from end of housing.
7. Place pressure plate spring in groove in pressure plate. Lubricate end plate with power steering fluid. Place end plate over spring. Using thumb pressure or arbor press, press end plate down to just slightly below retaining ring groove. Seat retaining ring in groove. Take care to prevent cocking end plate in bore or distorting assembly. Release pressure on end plate.
8. Using a punch, tap retaining ring ends around in groove until opening is opposite flow control valve bore. This ensures maximum retention of retaining ring. Install flow control valve spring in hole. Install flow control valve assembly with screened end towards front of housing.
9. Install new large "O" ring to outside of pump housing. Install "O" ring seals to countersunk holes for mounting studs and flow control valve. Lubricate inside edge of reservoir and install reservoir onto pump housing, aligning mounting stud holes. Install studs and snug tighten.
10. If necessary, tap reservoir down on pump housing using a soft-faced hammer. Install new "O" ring on pressure union groove next to hex head of fitting. CAUTION: DO NOT install "O" ring in lower groove on pressure union fitting. This will restrict relief outlet orifice.
11. Install pressure union fitting to pump housing and tighten to 11-16 ft. lbs. (15-22 N.m). Tighten mounting studs to 35 ft. lbs. (47 N.m). Remove pump from vise. Install mounting bracket and pulley. See «POWER STEERING PUMP R & I»(/ford/econoline-e350/1985-1999/remont/manual-power-steering/#steering-system-integral-power) .

Disassembly

1. Remove steering gear unit. See «STEERING GEAR R & I»(/ford/econoline-e350/1985-1999/remont/manual-power-steering/#steering-system-integral-power). Drain steering gear by holding gear unit upside down and turning input shaft several times. Mount gear in a soft-jawed vise with sector shaft cover upward. (Scheme 1)
2. Remove lock nut from sector shaft adjusting screw. Center steering gear by turning input shaft lock-to-lock while counting turns, then divide by two. From lock, turn shaft number of turns required to center sector shaft. If properly centered, flat surface on input shaft should be facing down.
3. Remove sector shaft cover bolts. Tap lower end of sector shaft with a soft faced hammer to loosen shaft in housing bore. Lift shaft and cover assembly from housing. Discard cover "O" ring. Remove sector shaft adjusting screw from cover.
4. Remove control valve housing attaching bolts and identification tag. Lift control valve housing and piston assembly from gear housing. Discard housing gasket. Remove Teflon ring and "O" ring from piston assembly. (Scheme 7)
5. Hold piston assembly over a clean container. Remove ball guide clamp screws, let guide tubes and balls fall into container. Rotate input shaft lock to lock until all 27-29 balls fall from piston into container. Remove worm and valve assembly from piston. Ensure that all balls have been removed from piston.
6. Install valve body assembly in bench mounted Holding Fixture (T57L-500-B) or soft jawed vise. Loosen Allen head race nut screw from valve housing. Remove worm bearing race nut using Wrench (T66P-3553-B), and Valve Housing-to-Piston Spacer (T66P-3553-C). (Scheme 8) Carefully slide input shaft, and worm and valve assembly out of control valve housing.

Scheme 7

Scheme 8

Note. Before reassembly, worm and valve sleeve, and control valve housing must be rebuilt. See WORM & VALVE SLEEVE and CONTROL VALVE HOUSING under OVERHAUL. Also, sector shaft seals must be replaced. See SECTOR SHAFT SEALS under OVERHAUL.

Scheme 9

1. Mount control valve housing in Holding Fixture (T57L-500-B) or vise with flanged end up. Using power steering fluid, lightly lubricate inside control housing bore and Teflon rings on valve sleeve. Carefully install input shaft and valve sleeve into control housing bore.
2. Install worm bearing race nut to housing. Tighten nut to 55-90 ft. lbs. (75-122 N.m). Install Allen head race nut set screw into control housing and tighten to 15-25 INCH lbs. (1.7- 2.8 N.m).
3. Place piston on bench with ball guide holes facing up. (Scheme 9) Insert worm shaft into piston so first part of worm groove lines up with first hole in center of piston. Place ball guide in piston. Place 27-29 ball bearings in ball guide while turning worm counterclockwise as viewed from input end of shaft.
4. If all balls have not been fed into guide upon reaching left stop, rotate input shaft in one direction and then other while inserting remaining balls. DO NOT rotate input shaft more than 3 turns from left stop or balls will fall out of circuit.
5. Secure guides in ball nut area of piston with ball guide clamp. Tighten ball guide clamp screw to 42-70 INCH lbs. (4.7-7.9 N.m). Dip new piston "O" ring in power steering fluid. Install it into piston groove. (Scheme 7) Install new Teflon seal ring to piston end groove using care not to over-stretch ring.
6. Apply petroleum jelly to Teflon seal ring on piston. Place new large "O" ring on control valve housing. Slide piston and control valve assembly into gear housing being careful not to damage piston Teflon seal ring.
7. Align oil passage in control valve housing with passage in gear housing. Place new small "O" ring in oil passage hole of gear housing. Loosely install housing attaching bolts and identification tag. Rotate piston so teeth are in same plane as sector shaft teeth. Tighten control valve housing-to-gear housing bolts to 30-45 ft. lbs. (41-61 N.m).
8. Place sector shaft cover "O" ring in gear housing. Turn input shaft to center piston. Apply petroleum jelly to sector shaft journal. Install sector shaft and cover into gear housing. Install and tighten sector shaft cover bolts to 55-70 ft.lbs. (75-95 N.m). Perform steering gear meshload over-center adjustment. See «STEERING GEAR MESHLOAD»(/ford/econoline-e350/1985-1999/remont/manual-power-steering/#steering-system-integral-power__steering-gear-meshload) under ADJUSTMENTS.

Scheme 10

1. After removing control valve from gear unit, remove dust seal from rear of valve housing using Puller Attachment (T58L-101-B) and Slide Hammer (T59L-100-B). Discard dust seal. Remove snap ring from valve housing. (Scheme 10)
2. Turn valve housing over. Insert Driver Handle (T65P-3524-A2) and Bearing/Seal Remover (T65-3524-A3). Tap bearing and seal out of housing. Discard oil seal. If inlet tube seats are damaged, remove seats using Tube Seat Remover (T74P-3504-L).

1. If inlet tube seats were removed, coat new seats with petroleum jelly and install using Tube Seat Installer (T74P-3504-M). Coat bearing and seal surface of housing with petroleum jelly.
2. Using Installer (T65P-3524-A1), press pre-lubed bearing into housing with metal covering facing out. Bearing should rotate freely after installation. If bearing does not rotate freely, to much pressure was used to install. Replace bearing.
3. Coat new housing oil seal in power steering fluid. Position seal into housing with metal side out. Using Installer (T65P-3524-A1), drive seal into housing but DO NOT fully seat seal yet. Remove Installer, squeeze snap ring and place on top of seal. Finish driving snap ring and seal inward until snap ring seats in groove.
4. Place new dust seal in housing with dished rubber side out. Using Installer (T65P-3524-A1), press inward until seal is located just behind undercut on input shaft. Apply generous amount of multi-purpose grease to area between seal lips.

After sector shaft has been removed from gear unit housing, remove snap ring from lower end of gear housing (sector shaft seal end). Using Puller Attachment (T58L-101-B) and Slide Hammer (T59L-100-B), remove dust seal and pressure seal from housing. Discard seals.

1. Lubricate new seals and seal bore with multi-purpose grease (Ford DOAZ-19584-AA). Place dust seal on Seal Installer (T77L-3576-A) so raised lip of seal faces installer. Place pressure seal on installer so lip faces away from installer. Flat side of each seal should be against each other. (Scheme 11)
2. Insert installer into sector shaft bore. Drive seals into bore until seals just clear snap ring groove. DO NOT bottom seals against bearing. Seals will not function properly if bottomed against bearing. Install snap ring into bore. Apply grease lightly to area between seal lips.

Scheme 11

WORM & VALVE SLEEVE

Note. Use only Seal Installation Set (T75L-3517-A) to install Teflon sealing ring to sleeve. Failure to use proper installation tools will cause damage to sealing rings and result in internal fluid leaks.

Disassembly & Reassembly

1. Remove Teflon sealing rings from valve sleeve using small-bladed knife. (Scheme 7) DO NOT scratch sleeve seal grooves. Wrap worm end of sleeve in shop towel and mount in soft-jawed vise. Place Mandrel (T75L-3517-A1) on sleeve. Install one valve sleeve Teflon ring over mandrel.
2. Using Pusher (T75L-3517-A2), rapidly push down on pusher forcing Teflon ring down mandrel cone and into fourth groove of valve sleeve. Repeat procedure for 3 more rings, adding another Spacer (T75L-3517-A3) under mandrel for each ring to line up with next open groove.
3. After all sleeve rings are installed, remove installation tools. Apply a light coat of power steering fluid to sleeve and Teflon rings. Reinstall one Spacer (T75L-3517-A3) on input shaft as a pilot for Sizing Tube (T75L-3517-A4). Slide sizing tube carefully over valve sleeve Teflon rings. Ensure rings are NOT being deformed when tube is slid over rings.
4. Allow sizing tube to sit over rings for minimum 5 minutes to help contract Teflon rings. Remove sizing tube. Check that rings turn freely in grooves. Install sleeve into control valve assembly soon after removing sizing tube.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• TROUBLE SHOOTING - BASIC PROCEDURES
• ADJUSTMENTS
• SPECIFICATIONS
• TORQUE SPECIFICATIONS
• HYDRAULIC SYSTEM BLEEDING
• STEERING GEAR UNIT
• WORM & VALVE SLEEVE
• STEERING GEAR MESHLOAD