Steering Gear - Manual Ford Festiva I

DESCRIPTION

Rack and pinion type steering is mounted by rubber insulators to the chassis bulkhead. Adjustment is provided for pinion gear preload. Pinion shaft is coupled to steering shaft. Tie rods connect end of rack to steering knuckles.

ADJUSTMENTS

Any adjustments needed are made during reassembly procedure. See STEERING GEAR OVERHAUL .

TROUBLE SHOOTING

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

Removal (Festiva)

1. Raise and support vehicle. Remove front wheels. Remove vehicle battery. Remove cotter pins and castle nuts from tie rod ends. Using tie rod puller, separate tie rod ends from steering knuckles. Remove the catalytic converter.
2. Remove plastic dust shield from right side lower inner fender panel. Mark the lower steering column "U" joint for reassembly reference and disconnect steering column and intermediate shaft and steering column. Remove steering gear bracket bolts. Lower steering gear until steering shaft is clear of column boot.
3. Slide steering gear to the right, through the inner fender tie rod opening until the left tie rod clears the left fender opening. Lower left side of steering gear until it can be removed from the left side. Ensure rack boots are not pinched or damaged during removal.

Removal (Tracer)

1. Raise and support vehicle. Remove front wheels. Remove vehicle battery. Remove cotter pins and castle nuts from tie rod ends. Using tie rod puller, separate tie rod ends from steering knuckles. Remove plastic dust shield from right side lower inner fender panel.
2. Remove band securing rubber boot to steering gear. Pull boot upward. Mark the steering gear pinion shaft and intermediate shaft lower "U" joint for reassembly reference. Remove bolt and washer securing steering shaft to intermediate shaft lower "U" joint. Remove steering gear bracket bolts. Lower steering gear until steering shaft is clear of intermediate shaft "U" joint. Remove steering gear through right side fender well tie rod opening.

Installation

To install, reverse removal procedure. Check and adjust toe-in. See WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES in WHEEL ALIGNMENT article.

Scheme 1

Disassembly

1. With steering gear removed from vehicle, place steering gear in a soft-jawed vise. Mark threaded portion of tie rod for reassembly. Remove tie rod ends. Remove boot band on large diameter side of gear housing.
2. Using a screwdriver or chisel, unstake lock tab washer. Clamp rack in a soft jawed vise and remove tie rod ball socket from end of rack. Remove both tie rods. Remove rack support yoke assembly housing.
3. Use a small screwdriver to remove oil seal from pinion shaft. Remove stop ring and snap ring. Grasp pinion shaft with pliers. Pull on pinion shaft while lightly tapping on gear housing with a soft hammer. Remove pinion assembly. Remove rack from pinion side of housing.

Inspection

1. Check rubber boots, ball bearings and tooth surface of rack for wear or damage. Using a dial indicator and "V" blocks, check rack for straightness. Maximum allowable runout is 0.012" (0.3 mm). If rack support bushings are worn, use a screwdriver to release the tab lock on the side opposite the pinion. Use blind hole Bearing Puller (D80L-100R) with slide hammer to remove bushing. Check tie rod ball joints for smooth operation. Replace parts as necessary.
2. Check sliding surface of rack support and gear housing for cracks or damage. Check rack bushing for excessive wear. Replace entire gear housing assembly if any of these parts are worn or damaged.

Reassembly

1. Apply lithium grease to ball bearing, roller bearing, inside of gear housing, lip of oil seal, sliding surface and back of rack support, sliding surface of rack bushing, rack pinion teeth and ball joints. If removed, install a new lower pinion bearing.
2. Carefully insert non-toothed side of rack into pinion end of housing as far as it will go. Position rack in housing so rack protrudes 2.68" (68 mm) from the left side of housing. Install pinion so that notch in pinion splines forms a 30 degree angle with the centerline of the housing. (Scheme 2) NOTE: If fit between housing and bearing is too tight, strike outer ring of bearing lightly while checking mesh of rack and pinion.
3. Install snap ring and spacer. Protect pinion shaft splines with tape and install new seal. Using a soft hammer, tap lightly on seal until it is flush with end surface of housing.
4. Mount rack in a soft-jawed vise and install new lock tabs and tie rods. Tighten tie rod with a "crows foot" wrench to 58-72 Ft. Lbs. (80-100 N.m). Use a center punch to stake lock tabs washer in 2 places. Slide tie rod boot over tie rod and position on rack. Secure with mechanic's tie wire. Install other boot and other boot clamps.
5. Install rack support yoke, spacer and spring in housing. Apply sealer to adjusting cover threads and install in housing. Install adjusting bolt and lock nut. Tighten adjusting cover to 29-43 Ft. lbs. (39-59 N.m). Tightening adjusting bolt to 8.7 INCH lbs. (1 N.m) and loosen 10-40 degrees from that position.
6. With rack centered in housing, measure pinion turning torque. DO NOT turn pinion past 90 degrees when measuring. Pinion turning torque should be 7.8-11.3 INCH lbs. (0.9-1.3 N.m). Adjust thrust yoke if not within specifications. Hold adjusting bolt with a wrench and tighten the lock nut with a "crows foot" to 7.2-10.8 ft. lbs. (10-15 N.m).
7. To complete reassembly, reverse disassembly procedure. Install tie rod ends and jam nuts. Ensure index marks made during disassembly align. (Scheme 1)

Scheme 2

WHEEL ALIGNMENT

After performing appropriate service procedures, refer to WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES article in the WHEEL ALIGNMENT section.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• STEERING GEAR OVERHAUL