Steering Columns: Removal & Installation Ford Windstar I

REMOVAL & INSTALLATION

Removal

1. Make sure that vehicle's front wheels are in the straight-ahead position and steering column shaft alignment mark is at the 12 o'clock position.
2. Disconnect battery ground cable.
3. Remove steering wheel. See «STEERING WHEEL»(ref-141798-S26633364672002071000000).
4. Remove steering column upper and lower steering column shrouds. See «LOWER STEERING COLUMN SHROUD»(ref-141798-S07136155632002071000000) and «UPPER STEERING COLUMN SHROUD»(ref-141798-S09808306692002071000000).
5. Disconnect three air bag sliding contact electrical connectors from main wiring harness at steering column instrument panel bracket.
6. Using door trim removal tool, remove air bag sliding contact electrical connectors from bend bracket.
7. Using door trim removal tool, disconnect two wire harness clips from column.
8. Remove key warning buzzer contact and anti-theft contact from ignition lock cylinder pocket of steering column lock cylinder housing.
9. Remove air bag sliding contact by pushing snap back at 6 o'clock position first, then 3 o'clock position, then 12 o'clock position and remove from steering shaft. (Scheme 1)

Installation

1. Make sure that the vehicle's front wheels are straight ahead and steering column shaft alignment mark is at the 12 o'clock position.
2. 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 lock cylinder housing.
3. Install air bag sliding contact cable clips into holes in steering column.
4. Install air bag sliding contact connector retainers into provided holes in steering column bend bracket.
5. Plug main wiring harness connectors into three air bag sliding contact connectors.
6. Install key warning buzzer contact and anti-theft contact into ignition lock cylinder pocket in steering column lock cylinder housing. Make sure contacts do not slip out of ignition lock cylinder pocket.
7. Install upper and lower steering column shrouds. See «LOWER STEERING COLUMN SHROUD»(ref-141798-S07136155632002071000000) and «UPPER STEERING COLUMN SHROUD»(ref-141798-S09808306692002071000000) .
8. Install steering wheel. See «STEERING WHEEL»(ref-141798-S26633364672002071000000) . Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-141798-S13641636782002070800000) .
9. Connect battery ground cable.
10. Verify air bag warning indicator operation.

Scheme 1

1. Disconnect negative battery cable.
2. Remove upper and lower steering column shrouds. See «LOWER STEERING COLUMN SHROUD»(ref-141798-S07136155632002071000000) and «UPPER STEERING COLUMN SHROUD»(ref-141798-S09808306692002071000000).
3. Disconnect the overdrive on/off switch electrical connector.
4. Remove the selector lever boot. (Scheme 2)
5. Use a small drift punch or suitable tool and drive the retaining pin from the steering column. (Scheme 3)
6. Remove the selector lever from the steering column. (Scheme 4)

To install, reverse the removal procedure.

Scheme 2

Scheme 3

Scheme 4

1. Remove bolt from upper U-joint-to-shaft connection. (Scheme 20) Collapse intermediate lower shaft. (Scheme 5)
2. Remove three nuts retaining steering gear sector shaft adjusting screw (primary).
3. Remove bolt retaining intermediate lower shaft assembly to steering gear input shaft.
4. From inside of engine compartment, remove intermediate lower shaft.

Note. Use new bolts to attach intermediate shaft to steering gear input shaft and steering column shaft to intermediate shaft.

1. From inside of engine compartment, install intermediate shaft through boot and to steering gear input shaft. Insert new bolt in U-joint and tighten bolt to specification. See «TORQUE SPECIFICATIONS»(ref-141798-S13641636782002070800000). (Scheme 20)
2. Extend shaft and insert into upper assembly U-joint at end of steering column. (Scheme 5) Insert bolt in U-joint and tighten bolt to specification. See «TORQUE SPECIFICATIONS»(ref-141798-S13641636782002070800000).
3. Check steering column for proper operation.

Scheme 5

1. Remove steering column. See «STEERING COLUMN (TILT)»(ref-141798-S05277620902002071000000).
2. Using pliers, remove steering column upper bearing spring. (Scheme 6)
3. Remove suspension height sensor control ring and steering column upper bearing tolerance ring. (Scheme 7)
4. Remove three screws and steering column lower bearing retainer. (Scheme 8)

To install, reverse removal procedure. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS .

Scheme 6

Scheme 7

Scheme 8

1. Disconnect battery ground cable.
2. Remove two screws and instrument panel steering column cover. (Scheme 9)
3. Remove three screws and instrument panel steering column cover reinforcement. (Scheme 10)
4. Unscrew and remove tilt wheel handle and shank, if equipped. (Scheme 11)
5. Remove three screws and lower steering column shroud. (Scheme 12)

1. Snap lower steering column shroud into place on upper steering column shroud. (Scheme 12)
2. Install three screws and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-141798-S13641636782002070800000).
3. Install tilt wheel handle and shank if equipped with tilt wheel. (Scheme 11)
4. Install instrument panel steering column cover reinforcement and three screws. (Scheme 10) Tighten screws to specification. See «TORQUE SPECIFICATIONS»(ref-141798-S13641636782002070800000).
5. Install instrument panel steering column cover and two screws. (Scheme 9) Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-141798-S13641636782002070800000).
6. Reconnect battery ground cable.

Scheme 9

Scheme 10

Scheme 11

Scheme 12

1. Install three electrical connectors to full engagement. Align multi-function switch mounting holes with corresponding holes in steering column tube casting.
2. Install two self-tapping screws, making sure to start screws in the previously tapped holes. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-141798-S13641636782002070800000) . Install upper steering column shroud and lower steering column shroud with screws. Tighten to .
3. Connect battery ground cable. Check tilt lock lever and multi-function switch for proper operation. specification. See «TORQUE SPECIFICATIONS»(ref-141798-S13641636782002070800000) .

1. Disconnect battery ground cable.
2. Remove two screws and instrument panel steering column cover.
3. Remove three screws and instrument panel steering column cover reinforcement.
4. Remove four nuts securing steering column absorber to steering column and remove steering column absorber.

To install, reverse removal procedure. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS .

Removal Precautions

Do not remove the steering column, steering wheel , and air bag module as an assembly from the vehicle unless the column is locked to prevent rotation. Lower end of steering shaft should be wired to prevent the steering wheel from being rotated and causing the air bag sliding contact to become mis-indexed.

All components of the steering column are assembled with fasteners which are designed to prevent loosening due to vibrations associated with normal vehicle operation.

1. Park vehicle with the wheels in a straight-ahead position.
2. Disconnect battery ground cable.
3. Remove steering wheel. See «STEERING WHEEL»(ref-141798-S26633364672002071000000).
4. Remove two screws and instrument panel steering column cover. (Scheme 9)
5. Remove three screws and instrument panel steering column cover reinforcement. (Scheme 10)
6. Remove two screws and steering column opening brace. (Scheme 13)
7. Disconnect electrical connectors between main wiring harness and steering column. Disconnect shift lock actuator. (Scheme 14)
8. Disconnect transaxle control selector indicator loop from transmission column shift selector tube. Remove screw and transmission range indicator from steering column. see scheme 2
9. Remove steering shaft-to-intermediate shaft universal joint pinch bolt. (Scheme 15)
10. Remove four nuts securing steering column absorber to steering column and instrument panel reinforcement.
11. Remove four nuts securing steering column to instrument panel reinforcement.
12. Lower steering column to floor.
13. Using screwdriver, snap shift cable and bracket off of selector lever arm. (Scheme 16)
14. Using screwdriver, lift tab on shift cable retainer and remove shift cable from bend bracket. (Scheme 17)and (Scheme 18).
15. Remove steering column from vehicle. (Scheme 19)

1. Position steering column on floor of vehicle.
2. Push shift cable retainer into slot on bracket and snap shift cable end onto shaft of transmission selector lever arm and support lever arm.
3. Insert steering gear input worm gear and rack into universal joint, making sure cutout in steering gear input worm gear and rack aligns with universal joint pinch bolt hole.
4. Raise steering column into position onto instrument panel reinforcement studs.
5. Install four nuts securing steering column to instrument panel reinforcement. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-141798-S13641636782002070800000).
6. Install steering column absorber and four nuts. Tighten nuts to specification. See «TORQUE SPECIFICATIONS»(ref-141798-S13641636782002070800000).
7. Install universal joint pinch bolt. (Scheme 20) Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-141798-S13641636782002070800000).
8. Install transmission range indicator. Connect cable loop to transmission column shift selector tube.
9. Connect main wiring harness to steering column electrical connectors. Connect shift lock actuator.
10. Install instrument panel steering column opening brace.
11. Install instrument panel steering column cover reinforcement and tighten screws to specification. See «TORQUE SPECIFICATIONS»(ref-141798-S13641636782002070800000).
12. Install instrument panel steering column cover and tighten screws to specification. See «TORQUE SPECIFICATIONS»(ref-141798-S13641636782002070800000).
13. Install steering wheel. See «STEERING WHEEL»(ref-141798-S26633364672002071000000).

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Scheme 18

Scheme 19

Scheme 20

1. Make sure the vehicle's front wheels are in the straight-ahead position.
2. Route air bag sliding contact wire harnesses through steering wheel opening at the three o'clock position. Position steering wheel on steering shaft so the alignment marks are aligned. Be sure air bag contact wire is not pinched.
3. Install NEW steering wheel retaining bolt and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-141798-S13641636782002070800000). (Scheme 24)
4. Connect horn/speed control wire harness to air bag sliding contact wire harness.
5. Connect air bag wire harness and horn wire harness from air bag sliding contact to driver side air bag module and install module to steering wheel. Make sure all air bag-to-steering wheel seams are flush and no gaps visible.
6. Tighten air bag sliding contact retaining screws to specification; then insert two steering wheel spoke covers. See «TORQUE SPECIFICATIONS»(ref-141798-S13641636782002070800000).
7. Connect battery ground cable. Verify air bag warning indicator.

Scheme 21

Scheme 22

Scheme 23

Scheme 24

To remove steering column lock lever, rotate the steering column lock lever counterclockwise. (Scheme 11)

To install, position steering column lock lever and rotate clockwise until tight. (Scheme 11)

1. Remove steering column. See «STEERING COLUMN (TILT)»(ref-141798-S05277620902002071000000).
2. Remove pinch bolt securing universal joint to intermediate shaft. (Scheme 15)
3. Remove universal joint.

To install, reverse removal procedure. Make sure pinch bolt hole lines up with cutout in intermediate shaft. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS .

1. Remove lower steering column shroud. See «LOWER STEERING COLUMN SHROUD»(ref-141798-S07136155632002071000000).
2. Turn ignition switch lock cylinder to RUN position.
3. Using flat-tipped punch, push on button below ignition switch lock cylinder and pull out ignition switch lock cylinder. (Scheme 25)
4. Using wide-blade screwdriver, pry loose LH instrument panel finish panel. Twist 45 degrees and remove light assembly from instrument panel finish panel. (Scheme 26)
5. Open instrument panel ash receptacle.
6. Remove two screws securing instrument panel lower center finish panel. (Scheme 27)
7. Using wide-blade screwdriver, pry loose instrument panel lower center finish panel. Pull lower finish panel away from instrument panel assembly. It is not necessary to disconnect electrical connections to center finish panel.
8. Remove two screws securing lower instrument panel opening finish panel. Pry loose panel. Hold instrument panel finish panel while prying loose right side of lower instrument panel finish panel. Remove finish panel. (Scheme 28)
9. Remove upper steering column shroud. (Scheme 29)

To install, reverse removal procedure. Ignition switch lock cylinder simply pushes back in. Tighten instrument panel finish panel screws to specification. See TORQUE SPECIFICATIONS .

Scheme 25

Scheme 26

Scheme 27

Scheme 28

Scheme 29

Note. For further steering column disassembly and reassembly information. see scheme 61, see scheme 62 and see scheme 63.