Ford Festiva. Manual — part 95

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STEERING SYSTEM - POWER

1991-92 STEERING Ford Motor Co. - Steering - Power Rack & Pinion

DESCRIPTION & OPERATION

Power steering system consists of a rack and pinion steering gear, valve body, power steering pump, fluid reservoir and interconnecting
hydraulic lines. Pressure and return lines from pump are connected to valve body. A vane-type power steering pump draws fluid from the
steering reservoir. Fluid is compressed by rotor and vanes inside steering pump and sent to steering gear. Pressure is monitored and controlled
by a pressure switch and a control valve located inside of steering pump.

TROUBLE SHOOTING

Refer to TROUBLE SHOOTING - BASIC PROCEDURES article in the GENERAL TROUBLE SHOOTING section.

LUBRICATION

CAPACITY

Information is not available.

FLUID TYPE

Use Dexron-II ATF type fluid.

FLUID LEVEL CHECK

Check fluid level before engine is started, while fluid is still cool. Remove reservoir cap fluid indicator on steering pump. Check fluid level.
Fluid should be between the "L" and "H" marks on the level gauge dipstick. If fluid is needed, fill to the "L" mark on dipstick. Run engine until
warm and turn steering wheel fully in both directions about 10 times. Return steering to straight-ahead position and shut engine off. Ensure
fluid level is between "L" and "H" marks. Add fluid if necessary.

HYDRAULIC FLUID BLEEDING

1. Raise and support front of vehicle. Ensure pump reservoir is filled to specified level. With ignition coil wire disconnected, crank engine

and add fluid to steering pump until fluid level remains constant. While cranking engine, rotate steering from stop to stop. Recheck and
add fluid as necessary.

2. Start engine and allow to idle for several minutes. Turn steering wheel completely lock-to-lock several times. Check fluid level. Add

fluid as necessary. Continue this procedure until there is no bubbling or decrease in fluid level.

ADJUSTMENTS

BELT TENSION

On Festiva, remove air duct and air cleaner. On all models, loosen steering pump mounting pivot bolt and the adjusting bolt lock nut. Using
Belt Tension Gauge (021-0028A), fit gauge to longest available belt span for testing. Adjust belt to specification. See

BELT TENSION

SPECIFICATIONS

. Tighten adjuster lock nut to 32-45 ft. lbs. (43-61 N.m) on Capri or 27-38 ft. lbs. (37-52 N.m) on Festiva.

BELT TENSION SPECIFICATIONS

REMOVAL & INSTALLATION

STEERING GEAR

Removal

1. Disconnect negative battery cable. On Capri, mark and loosen intermediate lower U-joint. On Festiva, mark and remove steering gear

intermediate shaft connecting steering gear to column shaft. On all models, disconnect high pressure and return lines and plug them.
Loosen front wheel lug nuts.

2. Raise vehicle. Remove front wheels. Remove tie rod end cotter pins and nuts. Separate tie rod ends from steering knuckles using Tie

Rod Remover (T85M-3395-A). Remove tie rod end splash shields. Remove right fender splash shield. Remove front catalytic converter
nuts and separate converter from inlet pipe.

3. Place reference marks on tie rod end and tie rod for reassembly reference. Loosen tie rod jam nut and remove right tie rod end. Remove

steering gear mounting bolts and washers. Slide steering gear to the left and pull right tie rod through fender opening. Remove steering
gear by sliding it to the right.

Installation

Application

(1)

Deflection: In.

(mm)

Gauge Tension:

Lbs. (kg)

New Belt

Capri & Festiva

.31-.35 (8-9)

110-132 (50-60)

Used Belt

Capri

.31-.35 (8-9)

110-132 (50-60)

Festiva

.35-.39 (9-10)

95-110 (43-50)

(1)

Apply approximately 22 lbs. (9.9 kg) of pressure.

1. Position steering gear in its mounting position. Attach intermediate shaft to steering gear pinion and tighten clamp bolt to 13-20 ft. lbs.

(18-26 N.m). Guide intermediate shaft into steering column hole. Lower vehicle.

2. Lift steering gear and align intermediate shaft with universal joint and install clamp bolt. Raise vehicle. Install steering gear mounting

bolts and tighten to 23-34 ft. lbs. (31-46 N.m). Install right tie rod end, using marks made during removal for installation reference.
Attach tie rod ends to steering knuckles. Install tie rod end nuts and tighten to 22-33 ft. lbs. (29-44 N.m).

3. Install tie rod end cotter pins. Attach catalytic converter to inlet pipe and install attaching nuts. Tighten nuts to 23-34 ft. lbs. (31-46

N.m). Install tie rod end splash shields. Install right fender splash shield. install front wheels. Lower vehicle.

4. Connect high pressure and return lines. Connect negative battery cable. Add power steering fluid and bleed air from system and check

for leaks. See

HYDRAULIC FLUID BLEEDING

under LUBRICATION.

POWER STEERING PUMP

Removal (Capri)

1. Remove right radiator support and brace. Remove pump drive belt. Disconnect intercooler outlet hose at throttle intake (if equipped).

Remove ground wire from engine lifting eye.

2. Remove pressure and return hoses and plug. Remove wire from pressure switch. Remove adjusting screw, nut and block from pump

bracket. Remove pivot bolt. Remove bracket retaining bolts then remove pump.

Removal (Festiva)

Remove air duct and air cleaner. Disconnect electrical connector from fluid pressure switch on power steering pump. Disconnect and plug
return and pressure lines. Remove adjustment bolt. Remove lock nut, washer and bracket bolt. Loosen mounting bolt and disconnect drive
belt. Remove mounting bolt. Remove power steering pump.

Installation (Capri & Festiva)

To install pump, reverse removal procedure. Adjust steering belt tension. Tighten all nuts and bolts to specification. See

TORQUE

SPECIFICATIONS

. Add power steering fluid and bleed air from system and check for leaks. See

HYDRAULIC FLUID BLEEDING

under LUBRICATION.

OVERHAUL

STEERING GEAR

Disassembly (Capri)

1. Remove steering gear and place in soft-jawed vise. Remove external hydraulic lines. See

Fig. 1

. Remove mount brackets and rubber

mount bushings. Remove brass tubing seats using a self-tapping screw and 2 screwdrivers.

Fig. 1: Exploded View of Power Steering Gear (Capri)

Courtesy of FORD MOTOR CO.

2. Use cold chisel to remove pinion shaft dust boot. Use No. 40 Torx bit to remove valve body attaching bolts. Remove, disassemble and

inspect valve body components. Remove burrs from spool valve with crocus cloth if necessary. Mark tie rod ends and jam nuts for
installation reference.

3. Remove tie rod ends and jam nuts. Remove tie rod dust boots. Use dull cold chisel to uncrimp tie rod end tab washers. Remove tie rod.

Remove adjusting plug, spring and yoke. Protect outer bulkhead with cloth and remove with pipe wrench.

4. Discard bulkhead "O" ring. Pull pinion shaft out from lower bearing side. Remove upper pinion bearing by driving it out with wooden

dowel. Remove rack from outer bulkhead end.

5. Remove inner guide and inner rack seal using Inner Rack Seal Remover T87C-3504-A. Mount rack on "V" blocks to check runout.

Runout should be no more than .012" (.03 mm). Replace rack if runout exceeds specification.

Reassembly

1. Install a new "O" ring on spool valve. Apply Long Life Lubricant (C1AZ-19590-BA) to pivot lever hole in spool valve and to pivot lever

hole in valve body. Apply ATF to rest of spool valve. Install spool valve. Apply Long Life Lubricant to pivot lever/collar and to
bushing.

2. Install pivot lever into spool valve housing. Make sure longest end of pivot lever/collar is seated in spool valve. Install end plug in spool

valve housing. Apply ATF to inner guide. Push inner guide and inner rack seal into rack housing with Inner Rack Seal Remover (T87C-
3504-A).

3. Apply Long Life Lubricant to rack teeth. DO NOT plug rack air hole with grease. Install Rack Oil Seal Protector (D83P-3504-K).

Install a new rack piston seal on rack using Piston Seal Replacer (T81P-3504-L) with Pusher (T75L-3517-A2) and Sizer (T81P-3504-
K).

4. Apply ATF to rack piston and cover rack with electrical tape. Coat inside of rack housing with ATF and carefully slide rack into

housing. Slide rack as far as it will go into housing. Remove rack seal protector. Install a new bushing into outer bulkhead using Pinion
Cover Centering Tool T18P-3504-Y.

5. Install a new sealing ring, oil seal and "O" rings at bulkhead end of rack housing. Lubricate all parts with ATF before installation. Wrap

outer bulkhead with towel and install with pipe wrench. Stake bulkhead to rack housing with punch. Install lower bearing on pinion
shaft. Install and tighten retaining nut to 29-36 ft. lbs. (40-50 N.m).

6. Stake nut to pinion shaft. Install pinion shaft into housing with rack extending 2.70" (68.7 mm) out of housing on pinion shaft end or

centered in housing. Also, notch on pinion shaft spline must be located 60 degrees from horizontal center. See

Fig. 2

.

Fig. 2: Installing Pinion Shaft (Capri)

Courtesy of FORD MOTOR CO.

7. Grease upper pinion bearing and install in housing using Upper Pinion Seal Replacer (T78P-3504-D). Tighten pinion bearing cover to

44-79 INCH lbs. (5-9 N.m). Then loosen it 10-20 degrees. Tighten lock nut to 29-36 ft. lbs. (40-50 N.m).

8. Using a new gasket, attach valve body to rack housing. Install yoke, spring, adjusting plug and lock nut. Tighten cover to 39-47 INCH

lbs. (4.5-5.5 N.m). Loosen cover 45 degrees. Measure pinion torque using inch lb. torque wrench and Pinion Adapter (T87C-3504-C).

9. Pinion torque should be .52-1.3 INCH lbs. (.6-1.5 N.m). If pinion torque is not within specification, loosen or tighten adjusting plug.

After pinion torque is set, tighten lock nut to 29-36 ft. lbs. (40-50 N.m). Mount steering gear in soft-jawed vise and install damper ring,
washer and tie rod.

10. Tighten tie rod to 43-58 ft. lbs. (60-80 N.m). Stake tab washer in 2 places. Position damper ring in washer. Install other damper ring,

washer and tie rod. Install tie rod dust boots and secure outer ends with clamps and inner sides with mechanics wire.

11. Install tie rod ends and adjust according to index marks put on during disassembly. Wrap electrical tape around and apply grease to

pinion shaft. Apply grease to lips of pinion shaft seal. Install pinion shaft seal using Pinion Bearing Replacer (T78P-3504-D).

12. Remove electrical tape from pinion shaft. Install support brackets and rubber bushings. Install external oil lines and 2 new copper

sealing rings.

Disassembly (Festiva)

1. Remove steering gear from vehicle and place in a soft-jawed vise. Remove fluid lines. See

Fig. 3

. Place reference marks on left tie rod

end and tie rod for reassembly reference. Loosen jam nut and remove left tie rod end. Remove outer boot clamps. Remove inner boot
wires. Remove boots.