Steering Columns: Overhaul Ford Windstar I

Disassembly

1. Remove steering column from vehicle. See «STEERING COLUMN (TILT)»(ref-141798-S05277620902002071000000) under REMOVAL & INSTALLATION.
2. Unscrew and remove tilt wheel handle and shank, if equipped. (Scheme 30)
3. Remove three screws and lower steering column shroud.
4. Turn ignition switch lock cylinder to RUN position.
5. Using flat-tipped punch, push on button below ignition switch lock cylinder and pull out ignition switch lock cylinder. (Scheme 31)
6. Remove upper steering column shroud.
7. Using door trim removal tool, remove air bag sliding contact electrical connectors from bend bracket.
8. Using door trim removal tool, disconnect two wire harness clips from steering column.
9. Remove key warning buzzer contact and anti-theft contact from ignition lock cylinder pocket of steering column tube flange.
10. Remove air bag sliding contact by pushing snap back at 6 o'clock position, then 3 o'clock position, then 12 o'clock position and remove from steering shaft. see scheme 4
11. Remove suspension height sensor control ring and steering column upper bearing tolerance ring. (Scheme 32)
12. Remove turn indicator cancel cam by pushing up with flat-bladed screwdriver. Note direction of flush surface. (Scheme 33)
13. Remove ignition switch. (Scheme 34) See appropriate STEERING COLUMN SWITCHES article in ACCESSORIES & EQUIPMENT for further information.
14. Remove upper bearing retainer snap ring and steering column upper bearing spring. (Scheme 35)
15. Remove steering column tube bearing sleeve and steering column upper bearing tolerance ring.
16. Remove gearshift lever
17. Remove brake/shift interlock solenoid retaining screws and remove solenoid assembly. (Scheme 36)
18. Remove shift control assembly and transmission shift selector position insert. (Scheme 37)
19. Using a drift, tap steering column lock actuator lever pin loose. Remove with diagonal pliers. (Scheme 38)
20. Remove plastic bearing retainer from bore of lock cylinder. (Scheme 39)
21. Remove steering column lock housing bearing from lock cylinder bore. (Scheme 40)
22. Remove steering column lock gear.
23. Remove two pivot bolts. (Scheme 41) Use caution as steering column position spring will release when bolts are removed. Remove steering column tube flange.
24. Remove steering shaft from steering column.
25. Remove upper and lower steering column lock actuators. (Scheme 42)
26. Remove steering column lower bearing retainer and steering column lower mounting bracket. see scheme 11
27. Remove tilt lock lever pivot pin using a drift. Remove steering column locking levers and springs. (Scheme 43)

Scheme 30

Scheme 31

Scheme 32

Scheme 33

Scheme 34

Scheme 35

Scheme 36

Scheme 37

Scheme 38

Scheme 39

Scheme 40

Scheme 41

Scheme 42

Scheme 43

Reassembly

1. Install steering shaft into steering actuator housing.
2. Install steering column lower bearing retainer and steering column lower mounting bracket. Tighten screws to specification. See «TORQUE SPECIFICATIONS»(ref-141798-S13641636782002070800000). see scheme 11
3. Install sensor ring, tolerance ring and spring to steering shaft. (Scheme 44)
4. Lubricate steering column lock actuators with Ignition Lock Grease F0AZ-19584-A (ESA-M1C232-A) or equivalent, prior to installation. Position steering column lock actuators in steering actuator housing. (Scheme 42)
5. Position steering column lock pawl in steering actuator housing and install steering lock with small hammer. Tap steering lock pawl pin in until flush with steering actuator housing. (Scheme 45)
6. Install lock lever spring and lock lever into housing using a drift to hold in place.
7. Install the other lever spring and lock lever with pin. Tap pin into place while driving out drift. (Scheme 46)
8. Support steering actuator housing in a vise and drive lock lever pin flush with steering actuator housing. (Scheme 47)
9. Place two nuts or spacers to hold steering column locking levers away from steering actuator housing. (Scheme 48)
10. Position steering column lock spring on steering column tube flange. With assistant, install steering column tube flange and pivot bolts. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-141798-S13641636782002070800000). (Scheme 41)
11. Install tolerance ring and sleeve over steering shaft to upper bearing. (Scheme 49)
12. Install steering column upper bearing spring and new snap ring on top side of steering column upper bearing spring using a 3/4-inch I.D. by 2-1/2 inch long PVC pipe. (Scheme 50)
13. Install turn indicator cancel cam, flush surface "up." (Scheme 51)
14. Install ignition switch. Align pin from ignition switch with slot in lock/column assembly. Position slot in lock/column assembly with index mark on casting. Ignition switch should be in RUN position. (Scheme 52)
15. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-141798-S13641636782002070800000). (Scheme 34)
16. Install steering column lock gear. Coat gear with Ignition Lock Grease F0AZ-19584-A (ESA-M1C232-A) or equivalent. (Scheme 53)
17. Lubricate steering column lock housing bearing. Lubricate with F0AZ-19584-A (ESA-M1C232-A) grease or equivalent. With actuator rack in 12 o'clock position, position bearing with tang inboard and in 5 o'clock position in lock cylinder. Insert tip of a screwdriver into double-D slot of bearing, then turn counterclockwise 90 degrees. (Scheme 54)
18. Install plastic bearing retainer. (Scheme 55)
19. Install shift control tube assembly (column shift only). (Scheme 56) Coat bushings with Steering Gear Grease C3AZ-19578-A or equivalent grease or equivalent. Tighten screws to specification. See «TORQUE SPECIFICATIONS»(ref-141798-S13641636782002070800000).
20. Install transmission shift selector position insert and brake/shift interlock solenoid assembly.
21. Align air bag sliding contact to column shaft and mounting tabs and slide onto shaft. Push on air bag sliding contact to snap three tabs onto steering column tube flange.
22. Install air bag sliding contact connector retainers into holes in steering column.
23. Install air bag sliding contact retainers into holes in steering column bend bracket.
24. Install key warning buzzer contact and anti-theft contact into ignition lock cylinder pocket in steering column tube flange. Make sure contacts do not slip out of ignition lock cylinder pocket. see scheme 28
25. Install upper steering column shroud.
26. Push ignition switch lock cylinder into place.
27. Install lower steering column shroud.
28. Screw in tilt wheel handle and shank and tighten, if equipped.
29. Install steering column assembly.

Scheme 44

Scheme 45

Scheme 46

Scheme 47

Scheme 48

Scheme 49

Scheme 50

Scheme 51

Scheme 52

Scheme 53

Scheme 54

Scheme 55

Scheme 56

Scheme 57

Scheme 58

Scheme 59