Electronic: Overhaul Ford Expedition I

Disassembly

1. Secure gear in vise with indexing flat pointed down. Rotate power steering gear input shaft and control from stop to stop, and then center gear. Remove steering gear sector shaft housing cover bolts.
2. Tap on lower end of steering gear sector shaft. Remove steering gear sector shaft. Remove locking nut from steering gear sector shaft adjustment screw.
3. Hold steering gear sector shaft. Turn housing over counterclockwise, and remove cover. Remove valve housing bolts and identification tag. Remove valve housing and piston assembly. Remove and discard gasket.
4. Remove bolts, steering gear ball return guide clamp and steering gear ball return guide. Rotate piston over container to collect 28 steering gear worm balls. Remove input shaft valve and housing assembly from piston. Remove and discard seal.
5. Install valve housing in bench mounted holding fixture, and loosen set screw. Using adjuster and lock nut wrench, remove race nut. Remove power steering gear input shaft and control from valve housing. Rotate valve housing with bench mounted holding fixture.
6. Remove power steering gear input shaft seal and dust seal. Remove input shaft snap ring. Rotate valve housing with bench mounted holding fixture. Using input shaft bearing seal remover, remove bearing and power steering gear input shaft seal.
7. Remove valve housing from bench mounted holding fixture. Install gear housing in bench mounted holding fixture, and remove steering gear sector shaft dust seal from sector shaft seal bore. Remove snap ring and spacer. Using appropriate puller, remove sector shaft seal.

Reassembly

1. Using multi-purpose grease (DOAZ-19584-AA) or equivalent, lubricate sector shaft seal bore and seal. Using sector shaft seal replacer, install sector shaft seal. Install spacer and snap ring.
2. Place steering gear sector shaft dust seal on sector shaft seal replacer. Ensure raised lip is toward tool. Lubricate steering gear shaft dust seal with (DOAZ-19584-AA) or equivalent. Using sector shaft seal replacer, install sector shaft dust seal. Remove steering gear housing from bench mounted holding fixture.
3. Position input shaft bearing in valve housing. Using input shaft bearing seal tool set and press, seat bearing and input shaft seal. Install input shaft snap ring. Using input shaft bearing/seal tool, install power steering gear input shaft dust seal.
4. Mount valve housing in bench mounted holding fixture. Install power steering gear input shaft and control into valve housing. Position power steering gear race nut into valve housing. Using adjuster and lock nut wrench, tighten race nut to specification. See «TORQUE SPECIFICATIONS»(ref-96306-S15729173112001040700000) table.
5. Install set screw. Remove valve housing from bench mounted holding fixture, and position piston on worm gear. Hold ball return guides until cap or clip is reinstalled. Install steering gear ball return guide on piston.
6. Ensure correct number of worm balls are installed for proper gear operation. Rotate piston while holding steering gear ball return guide and install 28 ball bearings into opening in ball guide. Position steering gear ball return guide clamp. Install bolts.
7. Install NEW gasket. Lubricate seal with multi-purpose grease and install seal on piston. Ensure oil passages align in steering gear housing. Install piston assembly into steering gear housing. Rotate teeth so they are on same plane as steering gear sector shaft.
8. Loosely, install valve housing bolts and identification tag, if equipped. Lubricate "O" ring on sector shaft housing cover. Rotate housing clockwise, and install sector shaft into sector shaft housing. Install sector shaft lock nut. Install sector shaft and housing assembly. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-96306-S15729173112001040700000) .