Steering box replacement

Tiny
JACKNUT
  • MEMBER
  • 2000 FORD F-150
  • 3.8L
  • V6
  • 2WD
  • MANUAL
  • 160,000 MILES
My steering box is leaking at the out put shaft for the steering arm. Can this be fixed with a seal? Or do I get a used one at junk yard?
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Sunday, May 5th, 2019 AT 10:30 AM

1 Reply

Tiny
JACOBANDNICKOLAS
  • EXPERT
Chances are it can, but there could also be an issue with o-rings and seals. Also, excessive wear on the output shaft can cause the leak. With that in mind, I am going to provide the complete overhaul directions and pics to help. I hate to say it, but it would be a lot easier to get a new one. LOL Regardless, here are the directions which include the replacement of all seals. The attached pics correlate with the directions. Check out the diagrams (Below). Please let us know what happens.

Disassembly

Note: The steering gear input shaft and seals cannot be repaired or replaced separately. Gear replacement may be necessary.
1. Secure the steering gear in a vise with the indexing flat pointed down. Use protective caps on the vise jaws.
2. Rotate the power steering gear input shaft and control from stop to stop and then center the gear.
3. Remove the steering gear sector shaft housing cover bolts.
4. Tap on the lower end of the steering gear sector shaft.
5. Remove the steering gear sector shaft.
6. Remove the locking nut from the steering gear sector shaft adjustment screw.
7. Remove the sector shaft housing cover.
Hold the steering gear sector shaft.
Turn the housing cover counterclockwise.
8. Remove the valve housing bolts and the identification tag.
9. Remove the valve housing and piston assembly.
10. Remove and discard the gasket.
11. Remove the ball bearings.
1 Remove the bolts.
2 Remove the steering gear ball return guide clamp.
3 Remove the steering gear ball return guide.
4 Rotate the piston over a container to collect the 28 steering gear worm balls.
12. Remove the input shaft valve and housing assembly from the piston.
13. Remove and discard the seal.
14. Install the valve housing in the Bench Mounted Holding Fixture and loosen the setscrew.
15. Use Adjuster and Locknut Wrench to remove the race nut.
16. Remove the power steering gear input shaft and control from the valve housing.
17. Rotate the valve housing with the Bench Mounted Holding Fixture.
18. Use the Puller to remove the power steering gear input shaft seal dust seal.
19. Remove the input shaft snap ring.
20. Rotate the valve housing with the Bench Mounted Holding Fixture, and use the Input Shaft Bearing/Seal Tool to remove the bearing and power steering gear input shaft seal.
21. Remove the valve housing from the Bench Mounted Holding Fixture.
22. Install the steering gear housing in the Bench Mounted Holding Fixture and remove the steering gear sector shaft dust seal from the sector shaft seal bore.
23. Remove the spacer.
1 Remove the snap ring.
2 Remove the spacer.
24. Note: The steering gear sector shaft bearing is not replaceable.

Use the Puller to remove the sector shaft seal.

Assembly

1. Lubricate the sector shaft seal bore.
Use Multipurpose Grease D0AZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A.
2. Use the Sector Shaft Seal Replacer to install the sector shaft seal.
Lubricate the sector shaft seal, using Multipurpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A.
3. Install the spacer.
4. Install the snap ring.
5. Note: Place the steering gear sector shaft dust seal on the Sector Shaft Seal Replacer so the raised lip is toward the tool.

Use the Sector Shaft Seal Replacer to install the sector shaft dust seal.
Lubricate the steering gear sector shaft dust seal; use Multipurpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-MIC159-A.
6. Remove the steering gear housing from the Bench Mounted Holding Fixture.
7. Position the input shaft bearing in the valve housing and use the Input Shaft Bearing/Seal Tool Set and a press to seat the bearing.
8. Use the Input Shaft Bearing/Seal Tool and a press to seat the power steering gear input shaft seal.
9. Install the input shaft snap ring.
10. Use the Input Shaft Bearing/Seal Tool to install the power steering gear input shaft dust seal.
11. Mount the valve housing in the Bench Mounted Holding Fixture.
12. Install the power steering gear input shaft and control into the valve housing.
13. Position the power steering gear race nut into the valve housing.
14. Use the Adjuster and Locknut Wrench to tighten the race nut.
15. Install the setscrew.
16. Remove the valve housing from the Bench Mounted Holding Fixture and position the piston on the worm gear.
17. WARNING: Hold the ball return guides until the cap or clip is reinstalled. Failure to hold the guides will result in a trapped ball or balls, which could cause a vehicle accident. If the ball guides become unseated at any time, remove all the balls and repeat the procedure.

Install the steering gear ball return guide on the piston.

18. WARNING: The correct number of balls are required for proper gear operation. Count the balls and insert each carefully.

WARNING: To make sure the balls are properly installed, rotate the steering gear input worm gear and rack from one end of travel to the other without allowing the poppet adjuster to contact the valve housing or moving the valve housing pilot face more than 69.1mm (2-3/4 inches) from the input end of the rack piston. If the steering gear input worm gear and rack cannot be rotated, reinstall the balls. If a steering gear is installed with a steering gear input worm gear and rack that cannot rotate, the steering gear will not function correctly and steering and gear failure can result.

Rotate the piston while holding the steering gear ball return guide and install the 28 ball bearings into the opening in the ball guide.

19. Install the steering gear ball return guide clamp.
1 Position the steering gear ball return guide clamp.
2 Install the bolts.
20. Install a new gasket.
21. Lubricate and install the seal on the piston.
Use Multipurpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-MlC159-A.
22. Note: Make sure to align the oil passages in the steering gear housing.

Install the piston assembly into the steering gear housing.
23. Rotate the teeth so they are on the same plane as the steering gear sector shaft.
24. Loosely install the valve housing bolts and the identification tag, if so equipped.
25. Lubricate the O-ring on the sector shaft housing cover.
Use Multipurpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A.
26. Rotate the housing clockwise and install the sector shaft into the sector shaft housing.
27. Note: The sector shaft lock nut will be tightened during the steering gear meshload adjustment.

Install the sector shaft lock nut.
28. Note: Loosely install the sector shaft housing bolts.

Install the sector shaft and housing assembly.

29. Tighten the bolts.

Check out the diagrams (Below). Please let us know what happens.
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Sunday, May 5th, 2019 AT 8:02 PM

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