Steering Gear - Power Ford Tempo I

DESCRIPTION

The type of steering gear used is a two-piece TRW unit. The steering gear is an 18.4:1 variable ratio unit.

TROUBLE SHOOTING

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

OPERATION

A hydraulic-mechanical unit with an integral piston and rack provides power-assisted steering control. Internal valving directs pump flow and controls pressure to reduce steering effort. Units contain a rotary fluid control valve and a boost cylinder integral with gear rack.

RACK PRELOAD

1. Rack preload adjustment is only required when the input shaft and valve assembly are removed. Do not remove external pressure tubes unless there is leakage or damage. If tubes are removed, replace them with new ones.
2. Remove steering gear from vehicle. See «STEERING GEAR R & I»(/ford/tempo/i-1983-1994/remont/manual-power-steering/#steering-gear-power) . Clean exterior of rack housing thoroughly. Remove hydraulic lines. Drain fluid out of openings. Mount gear in vise, near center of tube. Do not over tighten.
3. Loosen and remove adjusting plug lock nut. Back off plug one turn. Using Adjusting Plug Adapter (T81P-3504-U), tighten plug to 45 INCH lbs. (5 N.m).
4. Scribe gear housing in line with "O" mark on adjusting plug adapter. Back off plug so second mark on yoke plug adapter aligns with scribe mark on gear housing.
5. While holding adjusting plug stationary, use Adjusting Plug Lock Nut Wrench (T81P-3504-G) to tighten lock nut to 40-50 ft. lbs. (54-68 N.m). Refill steering gear with power steering fluid.

Scheme 2

Removal

1. Disconnect battery ground cable. Place ignition switch in "RUN" position. Remove access panel from floorboard (below steering column). Remove steering column boot retaining screws.
2. Slide boot up on intermediate shaft. Remove intermediate shaft-to-pinion shaft and intermediate shaft-to-steering shaft "U" joint clamp bolts. Spread slots enough to loosen intermediate shaft at both ends. Do not separate shafts.
3. Separate pressure and return lines at intermediate connections. Drain fluid. Remove pressure switch. Disconnect exhaust secondary air tubes at check valve.
4. Disconnect exhaust system at exhaust manifold intermediate connections. Mark position of tie rod ends for reassembly reference. Remove cotter pins and castle nuts from tie rod ends.
5. Using Tie Rod Puller and Adapter (T00L-33290-C and T81P-3504-W), separate tie rods ends from knuckles. Remove left tie rod end on manual transmission models.
6. On automatic transmission models, disconnect speedometer and shift cable assembly at transmission. Remove vehicle speed sensor (if equipped). Turn steering wheel to full left turn position.
7. Remove steering gear mounting brackets and grommets. Drape cloth over apron opening edges to protect dust boots during gear removal.
8. Separate steering gear from intermediate shaft by pushing up on shaft with a bar from underneath, while pulling steering gear down.
9. Rotate gear forward and down to clear pinion shaft through floorboard opening. With steering gear in full left turn position, move gear through right side apron opening until left tie rod clears left apron opening.
10. Lower left side of gear. Remove gear from vehicle. Hydraulic lines should remain on gear unless they are leaking, or gear housing is being replaced.

Installation

1. Rotate pinion shaft to full left turn stop. Move right front wheel to full left turn position. Insert right end of steering gear through right fender apron opening until left tie rod clears left fender apron.
2. Raise and insert steering gear left side through apron opening. Rotate gear so pinion shaft enters floorboard opening. With an assistant guiding intermediate shaft from inside vehicle, insert pinion shaft into intermediate shaft coupling.
3. Tighten clamp bolts hand tight. Install grommets and brackets. Ensure flat in left mounting area is parallel to dash panel. Tighten brackets in sequence. Start by tightening driver's side upper bracket bolt half tight.
4. Tighten driver's side lower bolt to specification, followed by driver's side upper bolt to specification. Finally, tighten passenger's side upper and then lower bolts to specifications.
5. Attach tie rod ends to steering knuckles. Tighten nuts to minimum specified torque. Tighten further as necessary to align slots with cotter pin holes. Install cotter pins.
6. On automatic transmission models, connect transmission shift cable and speedometer cable. Install vehicle speed sensor (if equipped). Install exhaust system. Connect secondary air tube at check valve.
7. Connect hydraulic lines at steering gear intermediate connections. Install pressure switch (if equipped). Tighten flexible coupling-to-pinion shaft clamp bolt first. Tighten intermediate shaft-to-steering shaft clamp bolts.
8. Install steering boot to floorboard. Install access panel. Turn ignition switch to "OFF" position. Connect battery ground cable. Fill system with fluid. Check and adjust toe-in (if necessary). Tighten tie rod end lock nuts.

1. Set steering in straight ahead position. Lock steering column. Raise and support vehicle. Place drain pan under steering gear. Remove boot clamps. Slide boots outboard from gear housing.
2. Thoroughly drain fluid from boots. Remove pinion cap. Remove pinion nut. Lower vehicle. From inside vehicle, remove column boot from floorboard.
3. Place protective cover on floor of vehicle. disconnect intermediate shaft from pinion shaft. It may be necessary to loosen steering column to separate intermediate shaft from pinion shaft.
4. Turn pinion shaft to center position so that "D" flat is in 3 o'clock position, and wheels are in straight-ahead position. Remove snap ring from gear housing.
5. Attach Pinion Shaft and Spool valve Puller (T81P-3504-T) to pinion shaft. (Scheme 3) Remove pinion shaft and valve assembly slowly to minimize oil spillage.
6. Insert Lower Pinion Seal Remover Guide (T81P-3504-E) along with Lower Pinion Seal Remover (T78P-3504-E) into pinion housing, and tap tool to bottom. Expand tool inside housing. Using large pair of pliers, remove seal and tool.

Scheme 3

1. Apply power steering fluid to pinion oil seal. Place seal over Lower Pinion Seal Replacer (T84P-3504-F) with lip of seal toward tool. Install seal in valve bore, seating it against shoulder.
2. Remove input shaft seal and bearing from valve assembly. Wipe oil from pinion gear teeth. Lubricate pinion gear teeth with steering grease. Insert Sizer (T81P-3504-M3) into valve housing.
3. Position "D" flat on input shaft to right and vertical (3 o'clock). Insert valve assembly in bore. Raise and support vehicle. Using Input Shaft Bearing Replacer (T81P-3504-R) to turn input shaft, verify that pinion is centered by counting number of turns from lock-to-lock.
4. If unequal number of turns are required to turn from lock-to-lock, remove valve assembly only far enough to move rack assembly one tooth at a time in either direction until it is equal.
5. Install input shaft bearing with wide face of case outward in valve bore. Seat with Input Shaft Bearing Seal Replacer (T81P-3504-R). Install Shaft Seal Protector (T81L-3504-P) over input shaft.
6. Apply a light film of grease to input shaft seal. Install seal with lip spring toward valve. Remove seal protector. Seat the seal until bottomed. Install snap ring in valve bore.
7. Reconnect intermediate shaft to pinion shaft. Tighten pinch bolts to specification. Tighten steering column bolts if column was loosened.
8. Install column boot to floorboard. Tighten screws to specification. With steering wheel locked, install new lock nut on pinion end of valve assembly.
9. Tighten lock nut to specification. Rack must be away from stops during this procedure. Install steering gear housing cap. Tighten cap to specification.
10. Install boots and boot clamps. Refill pump reservoir. Run engine. Cycle steering wheel from lock-to-lock several times. Recheck fluid level. Check for leaks.

Disassembly

1. Thoroughly clean exterior of steering gear. Mount steering gear in holding fixture. Place holding fixture in vise. Remove tie rod ends and lock nuts. Remove and discard dust boot retaining clamps. Remove boots and breather tube.
2. Holding rack on end of teeth, loosen ball joint nuts with Nut Wrench (T74P-3504-U). Remove tie rods with ball joints. Remove travel limiters (if equipped).
3. Using pinion Housing Cap Wrench (T83P-3504-AH), remove pinion shaft cap. Install Input Shaft Bearing Seal Replacer (T83P-3504-R). While holding pinion shaft, remove and discard pinion bearing lock nut.
4. Remove snap ring from housing. Attach Pinion Shaft and Spool Valve Puller (T81P-3504-T) onto pinion shaft. (Scheme 3) Remove pinion shaft and valve assembly slowly to minimize oil spillage.
5. Insert Lower Pinion Seal Remover Guide (T81P-3504-E, T78P-3504-E2 or D82P-3504-E1) along with Lower Pinion Seal Remover (T78P-3504-E) into pinion housing. Tap tool to bottom. Expand tool inside housing. Using large pair of pliers, remove seal and tool.
6. Remove rivet head with a sharp chisel. Using Roll Pin Remover (T78P-3504-N), push roll pin out of pivot bushing. Do not remove external hydraulic tubes. Using Adjusting Plug Lock Nut Wrench (T81P-3504-G), remove adjusting plug lock nut.
7. Using Adjusting Plug Wrench (T81P-3504-U), remove adjusting plug, spring and rack guide. Remove "O" rings from spool valve by pushing them to one side and cutting with a knife. Do not scratch or nick valve sleeve corners or flats.
8. Using Seal Remover (T81P-3504-E), remove lower pinion shaft seal. Insert tool assembly in valve bore until it bottoms. Tap lightly with plastic hammer to seat.
9. Using Slide Hammer (T50T-100-A), pull tool and seal from valve bore. Discard pinion seal. Using Slide Hammer and Attachment (T58L-101-A), remove lower pinion shaft bearing.
10. Inserting Lock Ring Tool (T77P-3504-A), engage end plate. Rotate tool clockwise until the lock ring retainer hole is visible. Rotate retainer clockwise until wire end is visible in slot. Remove retaining ring wire by leading wire out of slot while turning end plate counterclockwise.
11. If rack is difficult to remove, hand tighten a tie rod to rack gear. Place a slide hammer weight on tie rod. Install lock nut. Carefully remove rack. Using Expander (T81P-3504-B), remove and discard inner rack oil seal.
12. Oil seal contains a nylon ring that may separate during removal. Ensure all parts of seal are removed from housing. Remove piston plastic seal ring from rack. Remove "O" ring.
13. Place tool in a vise. Using Rack Oil Seal Remover (T78P-3504-L) and Adapter (T50T-100-A), remove seal. Remove "O" ring from rack bushing.

Scheme 4

Scheme 5

Scheme 6

1. Insert rack bushing into Rack Bushing Holder (T81P-3504-D), seal end first. Insert Holder (T81P-3504-K) into right end of rack housing. Install inner rack seal onto Driver (T81P-3504-C).
2. Tap tool handle with a plastic hammer to seat seal. Do not cock handle of tool. If tool binds in area of left turn pressure port, align flat on tool with pressure port.
3. Install "O" ring into piston groove. Apply grease on rack teeth and rack bearing sliding surface.
4. Insert Holder (T81P-3504-K) into right side of rack housing. Lubricate "O" ring and protective sleeve with power steering fluid. Using Protective Sleeve (D83P-3504-K), install rack into housing.
5. Lead protector sleeve in through right side opening of rack housing. Carefully push rack in until protective sleeve protrudes from left end. Remove protector and sleeve from rack. Install left tie rod to prevent rack teeth from damaging inner oil seal.
6. Apply power steering fluid to outer rack oil seal. Install "O" ring onto shock damper. Install outer oil seal, nylon washer, and shock damper onto Seal Installer (T81P-3504-C). Spring lip of seal must face inside of bushing.
7. Install Protective Sleeve (T81P-3504-N) into right side rack housing opening. Lubricate sleeve and "O" ring with power steering fluid. Apply hand pressure to seat shock dampener. Remove protective sleeve.
8. Install end plate on rack. Position end plate against shock damper. Use Driver (T77P-3504-A) to seat end plate if hand pressure will not.
9. Turn lock ring with Holder (T77P-3504-A) until retainer hole is visible. Insert lock wire. Rotate retainer clockwise until wire is completely enclosed. Rotate an additional 180 degrees.
10. Using Bearing Installer (T81P-3504-H), seat lower pinion shaft bearing against shoulder into pinion housing. Lubricate pinion oil seal with power steering fluid.
11. Using Seal Installer (T84P-3504-F), install seal with lip of seal facing tool. Mount assembly in soft-jawed vise. Position mandrel tool over pinion shaft. Lubricate with power steering fluid.
12. Using Mandrel Kit (T81P-3504-M1, M2, M3, M4), install 4 "O" rings in grooves of valve. Slide one ring over mandrel. Slide pusher tool over mandrel. By hand, force ring down ramp into fourth groove (closest to lock nut threads). (Scheme 5)
13. Slide sizing tool over rings after installation. Insert spacers after installation of each ring. The last "O" ring will snap into outboard groove directly off "O" ring installer. Remove sizing tool. Ensure rings are not cut, and that they turn freely in grooves.
14. Using Installer (T81P-3504-M3), install valve assembly into housing.
15. Ensure rack gear is centered. Align "D" flat facing 3 o'clock position. Count number of turns from stop to stop to ensure rack gear is centered.
16. If number of turns is unequal, rotate pinion shaft one tooth in direction that required the least turns from center. Repeat until correct. Center rack gear. Install and tighten pinion shaft lock nut.
17. Using Seal Installer (T81P-3504-R), seat pinion shaft dust seal. Install pinion bearing dust cap. Tighten dust cap to specification. Fill housing with gear lubricant.
18. Install rack guide, spring and adjusting plug. Set preload. Install lock nut. Hold one tie rod ball joint with an adjustable wrench while tightening other ball joint with Wrench (T81P-3504-G). This tightens both tie rods at the same time.
19. Install new roll pins in ball joint by tapping lightly with plastic hammer. Apply lubricant to groove on tie rods where dust boots clamp. Install dust boots and breather tube. Install new boot clamps. Install lock nuts on tie rods.
20. Apply lubricant to tip of rod threads. Install tie rod ends. Install steering gear. Check and adjust toe-in as necessary. Tighten tie rod end lock nuts.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• TROUBLE SHOOTING - BASIC PROCEDURES
• STEERING GEAR R & I