Ford Festiva. Manual — part 96
Fig. 3: Exploded View of Power Steering Gear (Festiva)
Courtesy of FORD MOTOR CO.
2. Remove tie rod lock nut pins using Lock Nut Pin Remover (T78P-3504-N). Remove tie rods from rack. Remove yoke plug lock nut
using Yoke Lock Nut Wrench (T90C-3504-BH). Remove yoke plug, spring and support yoke. Remove snap ring which retains pinion
and control valve assembly.
3. Remove seal using Lock Nut Pin Remover (T78P-3504-N). Remove valve housing attaching bolts. Remove valve housing and pinion and
control valve assembly. If present, remove shims from steering gear housing. Remove "O" ring. Remove lower pinion bearing using
Collet (D80L-100-L) and Blind Hole Puller Set (D80L-100-A).
4. Remove pinion and control valve assembly from valve housing by tapping lightly with a rubber mallet. Remove 4 Teflon seals from
pinion and control valve assembly. Press bearing out of valve housing using Pinion Seal Replacer (T88C-3504-MH) and Handle (T87P-
3504-D).
5. Using Outer Box Torque Adapter (T88C-3504-CH), rotate the rack bushing until the hooked end of the retaining wire is aligned with
the slot in the steering gear housing. Pry the retaining wire from the bushing hole. Rotate the bushing and remove the retaining wire.
Remove the rack from the right side of the steering gear.
6. Remove bushing from rack. Remove "O" ring. Remove seal using Rack Oil Seal Remover (T87C-3504-A) by bottoming seal into rack
with plastic hammer. Pull seal out with Slide Hammer T50T-100-A. Remove the rack mounting brackets and grommets.
Reassembly
1. Install grommets and mounting brackets. Install new seal using Rack Oil Seal Replacer T81P-3504-C. Install new "O" ring using Piston
Seal Replacer (T81P-3504-L) and Rack Piston Seal Sizer (T81P-3504-K). Place Short Rack Seal Replacer (T81P-3504-N) over end of
rack to protect bushing.
2. Install bushing on rack. Place Rack Seal Protector (T87P-3504-H) on rack. See
Fig. 4
. Install rack. Remove rack seal protector. Insert
rack retaining wire through slot and into bushing hole. Install retaining wire using Outer Box Torque Adapter (T88C-3504-CH).
Fig. 4: Installing Rack Seal Protector (Festiva)
Courtesy of FORD MOTOR CO.
3. Install lower pinion bearing using Pinion Bearing Replacer (T90C-3504-DH). If valve housing, steering gear, or pinion and control valve
assembly have been replaced, go to step 4). If none of these components have been replaced, go to step 6).
4. Measure valve housing, lower bearing and spacer, and steering gear housing. See
Fig. 5
. Use the following formula to determine proper
shim thickness: T = A C - B Where "T" is the shim thickness.
Fig. 5: Determining Replacement Shim Thickness (Festiva)
Courtesy of FORD MOTOR CO.
5. Having calculated required shim thickness, divide the required shim thickness by .0020" (.05 mm). This is the thickness of replacement
shims. Round off to the nearest equal shim thickness.
6. Install previously removed shim(s) into valve housing. Install new Teflon pinion seals on pinion and control valve assembly using Pinion
Valve Seal Installation Set (T81P-3504-M). Install first seal (seal closest to bearing) by sliding Mandrel (T81P-3504-M1) over valve
assembly to first seal groove.
7. Push seal into groove with Pusher (T81P-3504-M2). Size the seal by sliding large end of Sizer (T81P-3504-M3) over seal. Before
installing second seal, place Spacer (T81P-3504-M4) on valve assembly near splined end. Install and size using Mandrel (T81P-3504-
M1) and Pusher (T81P-3504-M2).
8. Before installing third seal, place 2 Spacers (T81P-3504-M4) on valve assembly near splined end. Install and size third seal. To install
fourth seal, turn second spacer around so the small ends of each spacer are facing. Install an size fourth seal.
9. Insert pinion and control valve assembly into valve housing, making sure it seats properly. Install New "O" ring. Install valve housing
mount bolts and tighten to 15-19- ft. lbs. (21-25 N.m). Install upper pinion bearing and seal using Pinion Seal Replacer/Torque Adapter
(T90C-3504-EH).
10. Install snap ring, support yoke and spring. Install yoke plug and tighten to 86 INCH lbs. (9.8 N.m). Loosen yoke plug and install Yoke
Plug Torque Gauge T90C-3504-CH over yoke plug. Tighten yoke plug to 38-48 INCH lbs. (4.4-5.4 N.m). Make scribe mark on support
yoke at zero point on yoke plug torque gauge.
11. Loosen yoke plug until 45 degree mark on yoke plug torque gauge is aligned with scribe mark on support yoke. Apply sealant to
exposed threads of yoke plug. Install lock nut and tighten to 36-43 ft. lbs. (49-59 N.m). Install tie rods and tie rod lock pins. Install
boots, boot wires and clips, and fluid lines.
POWER STEERING PUMP
Disassembly (Capri)
1. Drain pump. Remove rear bracket, mount bolts and brackets. Remove reservoir and "O" ring. Remove rear pump body and "O" ring.
Remove pump center body and "O" ring. Remove cam ring and pump shaft snap ring. Remove vanes from rotor. See
Fig. 6
.
2. Remove rotor from shaft and note rotor position. Remove pump shaft from front of pump. Remove front bracket. Remove shaft oil seal.
Check clearance between vane and rotor. Clearance should .0004-.0024" (.01-.06 mm). Replace vanes as necessary.
3. Check clearance between bushing and shaft. Clearance should be .001-.004" (.03-.1 mm). Replace shaft or bushing as necessary.
Fig. 6: Exploded View of Power Steering Pump (Capri)
Courtesy of FORD MOTOR CO.
Reassembly (Capri)
1. Install pressure switch and pressure regulator valve (if removed). Lubricate and install a new shaft oil seal. Install front bracket and
bolts. Install pump shaft from front of body. Install rotor onto rear of shaft in same position as removed.
2. Install shaft snap ring. Tap shaft on rear to seat snap ring onto rotor splined hole below rotor rear face. Install vanes in rotor with
rounded edges facing out. Install cam ring, center pump body and front "O" ring. Install rear pump body and "O" ring.
3. Install reservoir and "O" ring. Install short bolt into hole used by reservoir bracket. Install rear mount bracket. Rotate pulley to check for
smooth operation.
Disassembly (Festiva)
1. With pump removed from vehicle, secure pump in a soft-jawed vice. Remove nut and washer that secure high pressure line. Remove cap
screw and support bracket. Remove high pressure line. Remove return line attaching bolts. See
Fig. 7
and
Fig. 8
.
Fig. 7: Power Steering Pump Mounting & Pressure Hose (Festiva)
Courtesy of FORD MOTOR CO.
Fig. 8: Exploded View of Power Steering Pump (Festiva)
Courtesy of FORD MOTOR CO.
2. Remove return line and "O" ring. Remove pulley nut and washer. Remove pulley using Pulley Remover (OTC-1024). Remove keyway,
front bracket bolts and washers. Remove front bracket, rear bracket bolts and washers and rear bracket. Remove rear body bolts and
washers. Remove rear body. Remove shaft retaining ring. Remove shaft and rotor.
3. Remove vanes, "O" ring, and center body. Remove "O" ring and cam ring. Remove seal using Collet (D80L-100-Q) and Slide Hammer
(T50T-100-A). Remove valve fitting. Remove 4 "O" rings from valve fitting. Remove control valve, spring, pressure switch fitting and
spring. Remove "O" ring from pressure switch fitting. Remove spring seat. Remove plunger.
Reassembly (Festiva)
1. Coat pump vanes, rotor and control valve with ATF. Install new "O" ring on pressure switch fitting. Install plunger, spring seat, spring
and pressure switch fitting. Install new "O" rings on valve fitting. Install spring, control valve and valve fitting. Coat lip of new seal with
grease and install seal using suitable installer.
2. Install cam ring, new "O"ring, center body, new "O" ring and rotor. Ensure rounded edge of vanes face toward center of rotor. Install
vanes, shaft and retaining ring. Position rear body and install washers and bolts. Position rear bracket and install washers and bolts.
Position front bracket and install washers and bolts.
3. Position key in keyway and install pulley. Install pulley washer and nut. Tighten nut to 22-29 ft. lbs. (29-39 N.m). Install new "O" ring
at return line port. Position high pressure line and install support bracket and cap screw. Install high pressure line attaching washer and
nut. Tighten to 29-36 ft. lbs. (39-49 N.m).
4. Ensure pump rotates freely. If not, disassemble and repair as necessary. Install pump on vehicle. Bleed air from hydraulic system before
starting engine. See
HYDRAULIC FLUID BLEEDING
under LUBRICATION.
WHEEL ALIGNMENT
After performing appropriate service procedures, refer to
WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES
article in the
WHEEL ALIGNMENT section.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Ft. Lbs. (N.m)
Pinion Cover Lock Nut
29-36 (40-50)
Pinion Shaft Nut
29-36 (39-49)
Power Steering Pump Bracket
27-38 (37-52)
Power Steering Lock Nut
32-45 (43-61)
Tie Rod-To-Rack
44-58 (60-80)
Tie Rod-To-Steering Knuckle
26-29 (35-40)
Valve Body Cover Lock Nut
29-36 (40-50)
Wheel Lug Nut
67-88 (90-120)
INCH Lbs.
Pinion Bearing Cover
39-47 (4.5-5.5)
Application
Ft. Lbs. (N.m)
Intermediate Shaft Clamp Bolt
13-20 (18-26)
Pinion Adjusting Plug Lock Nut
36-43 (49-59)
Pressure Hose Fitting
29-36 (39-49)
Power Steering Pump Lock Nut
27-38 (37-52)
Power Steering Pump Mounting Bolt
27-40 (36-54)
Steer Gear Mount Bolts
23-34 (32-47)
Tie Rod-To-Steering Knuckle
22-33 (30-45)
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