Power Steering: Removal & Installation Ford Thunderbird XI

Removal & Installation

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1. Raise and support the vehicle. For additional information, refer to «JACKING & HOISTING»(ref-232595-S06496072622006051700000) article .
2. Remove the screw, pushpin and the shield.
3. Remove the screws and the air deflector.
4. Remove the bolt.
5. Remove the bolt, bracket and bushings.
6. Remove the bolt.
7. Unclip the retainer.
8. Pull the hose rearward between the oil pan and the radiator support crossmember.
9. Remove the bolt and the bracket.
10. Disconnect the hose at the pump. Drain the fluid into a suitable container.
11. Remove the bolt.
12. Disconnect the hose at the steering gear.
13. Unclip the retainer and detach the hose.
14. Remove the hose.
15. To install, reverse the removal procedure. Using the special tool, install a new Teflon(R) seal.
16. Fill and leak check the system. For additional information, refer to «STEERING SYSTEM-GENERAL INFORMATION»(ref-204554) .

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1. Remove the A/C condenser core. For additional information, refer to «AIR CONDITIONING»(ref-204570) .
2. Remove and discard the six clamps.
3. Disconnect the hoses. Plug the hoses and the cooler (3D746).
4. Remove the cooler. Remove two bolts. Lift the cooler from the retainers and remove the cooler.

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1. Install the cooler. Position the cooler on the retainers. Install two bolts.
2. Position new clamps on the hoses.
3. Unplug the hoses and the cooler. Connect the hoses.
4. Using the special tool, tighten the clamps.
5. Install the A/C condenser. For additional information, refer to «AIR CONDITIONING»(ref-204570) .
6. Fill, purge and leak check the system. For additional information, refer to «STEERING SYSTEM-GENERAL INFORMATION»(ref-204554) .
7. Check and fill the transmission. For additional information, refer to «SERVICING - A/T»(ref-141346) .
8. Fill the cooling fan reservoir. For additional information, refer to «ENGINE COOLING»(ref-204560) .

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Note. New Teflon(R) seals must be installed any time the lines are disconnected from the steering gear.

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1. Hold the steering wheel in the straight-ahead position using a suitable holding device.
2. Remove the wheel and tire assemblies.
3. Remove the nuts and disconnect the tie-rod ends. Discard the nuts.
4. Disconnect the electrical connector.
5. Loosen the bolt.
6. Remove the pinch bolt and disconnect the intermediate shaft.
7. Remove the bolt and disconnect the power steering hose bracket.
8. Disconnect the power steering hoses. Plug the hose ends and the gear. Discard the seals.
9. Remove the nuts, bolts and the power steering gear (3504). Discard the nuts.
10. To install, reverse the removal procedure.
11. Using the special tool, install new seals (388898-S) on the power steering hoses.
12. Fill and leak check the system. For additional information, refer to «STEERING SYSTEM-GENERAL INFORMATION»(ref-204554) .
13. Check wheel alignment. Adjust as necessary. For additional information, refer to «SPECIFICATIONS & PROCEDURES»(ref-232595) .

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Removal

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1. Remove the wheel and tire assembly.
2. Loosen the tie-rod end jam nut.
3. Remove the nut and detach the tie-rod end from the wheel knuckle.
4. Remove the tie-rod end.
5. Remove the tie-rod end jam nut.
6. Remove the inner and outer front suspension steering ball stud boot seal clamps.
7. Remove the front suspension steering ball stud boot seal.
8. Using the (A) special tool, remove the (B) front wheel spindle tie-rod.
9. Thoroughly clean and inspect all the parts to be reused. Replace the parts as necessary.

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1. Lubricate the front wheel spindle tie-rod inner groove with steering gear grease where the front suspension steering ball stud boot seal is clamped. Check that the front suspension steering ball stud boot seal is positioned correctly over the steering gear housing bead at the large Inside Diameter (ID) and is in the front wheel spindle tie rod groove at the small ID. Check that the front suspension steering ball stud boot seal is not twisted and the breather tube is securely inserted into the breather nipple at both front suspension steering ball stud boot seals.
2. To install, reverse the removal procedure.
3. Check the wheel alignment. Adjust as necessary. For additional information, refer to «SPECIFICATIONS & PROCEDURES»(ref-232595) .

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1. Raise the vehicle on a hoist. For additional information, refer to «JACKING & HOISTING»(ref-232595-S06496072622006051700000) .
2. Disconnect the electrical connector.
3. Remove the bolt and disconnect the power steering hose bracket.
4. Disconnect the power steering hoses. Plug the hose ends and the gear.
5. Remove the control valve actuator.
6. To install, reverse the removal procedure.
7. Using the appropriate special tool, install new O-rings on the power steering hose fittings.

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1. Position the power steering gear (3504) in a vice with protective caps.
2. Mark the jam nuts and the tie-rods for installation reference.
3. Loosen the jam nuts and remove the tie-rod ends (3A130).
4. Remove the jam nuts.
5. Remove the boot clamps and the boots.
6. While holding the rack, remove the tie-rods.

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1. While holding the rack, install the tie-rods.
2. Position new inner clamps on the boots.
3. Position the boots on the gear, making sure the air tube is correctly installed in the boots and aligned between the locating marks on the gear housing.
4. Using the special tool, tighten the clamps.
5. Install the clamp.
6. Install the jam nuts to the marks made during installation.
7. Install the tie-rod ends.