Ford 1L1Z-3504-AARM
Gear Assembly

Service and repair procedures for the rack and pinion should start with the vise positioning which holds the rack and pinion by its indexing flat in a pointing downward direction while protecting vise jaws with caps. First center the rack while rotating the power steering input shaft and control between its full stops. Bolt release the rack and pinion sector shaft housing cover along with a tap on the lower end of the rack and pinion sector shaft for its removal. The next step involves two procedures: first disconnect the locking nut from the adjustment screw on the rack and pinion sector shaft and second rotate the sector shaft housing cover counterclockwise after holding the shaft. Tear down the valve housing bolts followed by the identification tag before extracting the piston assembly, valve housing. Throw away the gasket when done. The next step entails rotating the piston above a container whereby the 28 rack and pinion worm balls can be collected after the removal of the rack and pinion ball return guide clamp and ball return guide and ball bearings. Take out the input shaft valve and housing assembly from the piston while discarding the seal. The valve housing receives installation into a Bench Mounted Holding Fixture where a setscrew achieves loose positioning before swapping it with an Adjuster and Locknut Wrench to detach the race nut. The power steering rack input shaft and control should be taken out from the valve housing as you rotate the valve housing with the fixture. A Puller tool enables removal of the power steering rack input shaft seal dust seal before the input shaft snap ring can be extracted. The Input Shaft Bearing/Seal Tool allows you to extract both the bearing and the power steering rack input shaft seal while rotating the valve housing. Move the valve housing from the fixture while you add the rack and pinion housing. The process requires removal of the sector shaft dust seal from the seal bore and the spacer. A Puller must remove the sector shaft seal because the bearing on the rack and pinion sector shaft cannot be replaced. Place Multi-Purpose Grease DOAZ-19584-AA or equivalent equivalent to Ford specifications ESB-M1C93-B and ESR-M1C159-A into the sector shaft seal bore before installing the sector shaft seal using the Sector Shaft Seal Replacer that must also be lubricated. Position the dust seal of the rack and pinion Sector Shaft onto the Sector Shaft Seal replacer with its raised lip facing the tool. Apply lubrication before assembly and install the spacer. Position the input shaft bearing into the valve housing while using the Input Shaft Bearing/Seal Tool Set and press. Then install the power steering rack input shaft seal. The power steering rack input shaft dust seal together with its snap ring should be installed with help from the Input Shaft Bearing/Seal Tool. Install the valve housing on the fixture and insert the power steering rack input shaft together with its control unit at the correct spot before tightening the power steering rack race nut using the Adjuster and Locknut Wrench. The valve housing receives a purchased setscrew before the fixture releases the housing to match the piston onto the worm gear. Secure the ball return guides during cap or clip reinstallation to prevent ball trapping before adding the rack and pinion ball return guide to the piston with precise ball number insertion. Verify the proper ball installation in the worm gear input of the steering mechanism by rotating it together with the rack. Replace any improperly installed balls. Install the piston by first rotating it before placing 28 ball bearings into the opening of the ball guide while grasping the steering control ball return guide. The procedure ends with installing the clamp and bolts onto the ball guide. The procedure requires users to install a new gasket followed by applying Multi-Purpose Grease DOAZ-19584-AA or its equivalent to the piston seal before solving and aligning the rack and pinion housing oil paths. First move the teeth into position with the rack and pinion sector shaft while fitting the valve housing bolts and ID tag loosely before clockwise rotation of the housing towards the sector shaft installation. The sector shaft lock nut will be adjusted during the mesh load procedure but it must first be installed then all bolts will be tightened securely after installation of the sector shaft housing bolts.