Steering Gear - Manual Ford Tempo I

DESCRIPTION

The steering system is rack and pinion type. Steering gear is connected to steering knuckles with tie rods. The input shaft connects to the steering shaft with double "U" joint intermediate shaft.

RACK PRELOAD

Rack preload is adjusted during reassembly procedure. See OVERHAUL in this article.

TROUBLE SHOOTING

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

Removal

1. Disconnect battery ground cable. Turn ignition switch to RUN" position. Remove access panel from floorboard, below steering column. Remove intermediate shaft "U" joint bolts at pinion shaft.
2. Using a screwdriver, spread slots enough to loosen intermediate shaft at both ends. Intermediate shaft and pinion shaft can not be separated at this time.
3. Remove tie rod end cotter pins and castle nuts. Using a tie rod end puller, separate tie rod ends from steering knuckles. Turn right wheel to full left turn position.
4. Disconnect speedometer cable at transmission (automatic only). Disconnect secondary air tube at check valve. Remove exhaust system from exhaust manifold.
5. Remove steering gear mounting brackets and insulators. Turn steering wheel full left. Separate gear from intermediate shaft by having an assistant pull up on shaft from inside vehicle.
6. Carefully rotate gear forward and down to clear pinion shaft through floorboard opening. Ensure pinion shaft is in full left turn position.
7. Move gear through passenger side apron opening until left tie rod clears shift linkage. Lower gear left side. Remove steering gear. Do not rip boots.

Installation

To install, reverse removal procedure. Ensure flat on side mounting area is parallel to floorboard. Tighten left mounting bracket first to locate gear properly. Check and adjust toe-in as necessary.

Scheme 1

Disassembly

1. With steering gear removed, clean housing exterior. Mount housing in Holding Fixture (T57L-500-B). Loosen tie rod end lock nuts. Remove tie rod ends. Remove outer boot clamps.
2. Remove and discard inner boot clamps. Remove boot. Turn gear full right to expose rack teeth. Mount rack teeth in soft-jawed vise. Using pipe wrench on inner tie rod ball socket, remove and discard tie rod.

Inspection

Visually inspect rack end for corrosion or contamination. If either is present, overhaul or replace steering gear. See STEERING GEAR OVERHAUL .

Scheme 2

1. Turn gear full right turn to expose rack teeth. Mount rack teeth in a soft-jawed vise. Install new tie rods. Tighten to specification. Remove assembly from vise. Supporting ball socket, stake socket to rack with a punch.
2. Center of punch should be approximately.06" (1.5 mm) away from rack end. (Scheme 2) Visually verify displacement of metal into rack slot.
3. Grease rack and rack teeth. Install boots and boot clamps. Ensure small diameter of boot is in the tie rod groove. Install lock nuts and tie rod ends.

STEERING GEAR OVERHAUL

Note. If pinion is removed, the entire gear must be disassembled for cleaning. The pinion plug threads must be re-tapped and cleaned.

1. With steering gear removed, remove tie rod ends, lock nuts, dust boots and tie rods as previously described. Mount rack assembly in Holding Fixture (T57L-500-B). Remove and discard pinion shaft plastic cap.
2. Turn pinion fully right. Using Plug Remover (T86P-3504-A), remove and discard pinion plug. With plug remover reversed, remove and discard adjusting plug.
3. Remove spring and rack guide bearing. Remove pinion and bearing assembly by pushing out through the pinion plug opening. Use plastic mallet if necessary.
4. Remove rack from pinion end of housing. Using screwdriver, carefully pry out pinion shaft seal. DO NOT damage housing. Discard seal.

Cleaning & Inspection

1. Using Plug Remover (T86P-3504-A), clean threads of adjusting plug and pinion plug bore. Wash all parts in mineral spirits. Air dry all parts.
2. Do not submerge plastic rack bushing in right end of housing. Inspect rack bushing for wear. Check pinion teeth and rack for corrosion, wear, straightness, cracks, scoring, pitting or breaks.
3. Inspect the lower pinion bearing for wear or roughness. If any of these conditions exist, replace the rack housing. Replace all other parts as necessary.

Scheme 3

Scheme 4

1. If rack bearing was not removed, go to step 4). If rack bearing was removed, align 3 slots of Rack Bushing Guide (T86P-3504-C2) over dimples in rack tube. Align extra slot over one of tube slots. (Scheme 3)
2. Lubricate new rack bushing outer diameter with steering gear grease. Insert new rack bushing into tool so tabs align with grooves in tool.
3. Using Rack Bushing Replacer (T86P-3504-C1) and hand pressure, push rack bushing into rack tube until tool bottoms. Remove rack bushing guide. Reapply hand pressure to rack bushing replacer to fully seat tabs in slots.
4. Fill rack teeth and cover rest of shaft with a light film of grease. Pack pinion shaft lower bearing and inboard of rack bushing with grease. Install rack into housing from left end.
5. Center the load slot in pinion bore. Coat all remaining sliding surfaces with grease. Pinion shaft teeth and bearing with grease. Install pinion shaft and bearing assembly from bottom through load slot in rack.
6. Install pinion shaft plug. Tighten to specification. Install, but do not tighten, left tie rod assembly to rack. Mount gear to Holding Fixture (T57L-500-B).
7. Hold pinion shaft flat in 9 o'clock position while pushing rack into housing. Jiggle rack to engage rack to pinion and to start rack in rack bushing. Push rack in all the way.
8. The pinion shaft flat should stop in the 6 o'clock position when the left ball joint contacts the housing. (Scheme 4) If flat is not in the 6 o'clock position, repeat step 7) until it is.
9. Install, but do not tighten, right tie rod to rack. Install rack guide, preload spring and adjusting plug. Tighten plug until most of play in rack is taken up.
10. Turn pinion lock-to-lock, counting number of turns necessary. Return pinion half the number of turns to center position. Pinion shaft flat should be at 3 o'clock position.
11. The pinion gear has only 4 teeth, so flat can only be in one of 4 positions, 90 degrees apart. If out of adjustment repeat step 7).
12. Remove adjusting plug. Apply Loctite hydraulic sealant to plug threads. Tighten adjusting plug to specifications. With Pinion Torque Adapter (T86P-3504-B) mounted to a torque wrench, slowly turn pinion input shaft 1/2 turn in each direction from center.
13. Return to center position. Repeat twice, checking peak torque within 1/4 turn from center. Peak torque must be a minimum of 15 INCH lbs. (1.7 N.m) in either direction.
14. If not to specification, check adjusting plug bore threads for burrs. Repeat steps 12) and 13). Back off adjusting plug 30 degrees. Measure torque across center to ensure it is within specification.
15. Stake adjusting plug in 3 places equally spaced apart. Each stake should be midway between original stakes. Pack the space above pinion shaft needle bearing 2/3 full of steering gear grease.
16. Coat new pinion shaft seal lip with grease. Using Pinion Cover Installer (T81P-3504-Y) and hand pressure, press seal in until flush with top of housing.
17. Stake pinion plug in 2 places midway between original stakes. Fill plastic cap with grease. Using hand pressure install cap until bottomed on gear housing.
18. Wipe off excess grease. Install new inner tie rods, boots and boot clamps. Install tie rod end lock nuts and tie rod ends.

WHEEL ALIGNMENT

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

1. WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES (for Escort)
2. WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES (for Tempo & Topaz)

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• OVERHAUL
• STEERING GEAR OVERHAUL