Ford Falcon. Manual — part 92

211-02-21 Power

Steering 211-02-21

REMOVAL AND INSTALLATION (Continued)

15. Remove J 46221 from the valve spool shaft.

20. Lubricate the rack bearing assembly with o-ring

with lithium base grease.

NOTE: The spool shaft must be held in place

during the following step.

21. Install the following items into the gear assembly:

Rack bearing assembly with o-ring
Adjuster spring
New adjuster plug

16. Install the new metric hex nut onto the pinion

while holding the valve spool shaft.
NOTE: Tighten the metric hex nut to 30 Nm (22

lb. ft.).

22. Turn the adjuster plug clockwise onto the rack

17. Install the new dust cover to the rack and pinion

and pinion gear assembly until the adjuster plug

gear assembly.

bottoms in the rack and pinion gear assembly.
NOTE: Tighten the adjuster plug to 10 Nm (90 lb.

18. Install the new retaining ring into the groove in the

in.) then turn back 35 degrees to 55 degrees.

top of the valve assembly of the rack and pinion

gear assembly.

23. Flush and bleed power steering system. Refer to

19. Install the spool shaft boot.

Bleeding the Power Steering System procedure.
NOTE: Flush and bleed power steering system

(hoses, reservoir and cooler lines) with power

steering fluid.

24. Install the steering gear into the vehicle. Refer to

your dealership service manual.

Power Steering Pump (I6)

Removal
1. Using a 15mm socket, rotate the drive belt

tensioner clockwise to reduce belt tension and

remove belt.

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211-02-22 Power

Steering 211-02-22

REMOVAL AND INSTALLATION (Continued)

2. Remove pump and pulley as a whole unit by

Removal and Installation

accessing pump attaching hardware through

1. Remove the power steering pump pulley. For

holes in pulley OR

additional information, refer to Power Steering

3. Remove pump pulley using special tool #E9240

Pump Pulley (V8) in this section.

B.

2. Disconnect the power steering reservoir pump

hose and pressure line from the power steering

pump.

Drain the power steering oil reservoir.

4. Remove fluid from pump reservoir using a syringe

or syphon hose.

5. Loosen the pump pressure line connector and

detach pressure line. Detach return line.

3. Remove the three bolts and the pump.

CAUTION: Take care to prevent power

steering pump fluid loss by plugging

connections.

6. Remove pump retaining hardware and withdraw

pump from mount.

Installation
1. Position pump in front cylinder cover.
2. Install return line and torque hose clamp.
3. Install pump mounting hardware and torque to

specification.

4. Install pressure hose connector.
5. Install pump pulley using special tool No.

E9239-A.

4. To install, reverse the removal procedure.

6. Install the drive belt. Refer Figure 10 for routing.

NOTE: Install a new power steering seal on the

power steering pressure fitting by stretching the

NOTE: Ensure belt is correctly engaged on pulley

seal over the seal replacer until it is large enough

ribs.

to slip over the threads of the fitting.

7. Fill power steering pump reservoir with specified

5. Install the power steering pump pulley. For

fluid.

additional information, refer to Power Steering

8. Attach a remote starter switch and carry out start

Pump Pulley (V8) in this section.

up procedure.

6. Fill, purge and leak check the system as outlined

Power Steering Pump (V8)

in the relevant chapter.

Special Tool(s)

Teflon® Seal Replacer Set

211-D027 (D90P-3517-A) or

equivalent

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211-02-23 Power

Steering 211-02-23

REMOVAL AND INSTALLATION (Continued)

5. Loosen the tie rod end stud nuts and free the tie

Power Steering Pump Pulley (V8)

rod end stud tapers in the wheel spindles.

Remove the nuts and detach the tie rod ends

Special Tool(s)

from the spindles.

Steering Pump Pulley Remover

211-016 (T69L-10300-B)

Steering Pump Pulley Replacer

211-185 (T91P-3A733-A)

6. Remove the catalytic converter assembly as

Removal

outlined in the relevant section.

1. Remove the drive belt as outlined in chapter

7. Remove the two nuts securing the steering gear

Section 303-05.

to the cross-member and remove the gear from

2. Using the special tool, remove the power steering

the vehicle.

pump pulley (3A733).

Installation

Installation

1. Position the steering gear assembly on the

1. Using the special tool, install the power steering

cross-member, install and tighten the securing

pump pulley (3A733).

nuts.

2. Install the drive belt as outlined in chapter Section 2. Connect the tie rod ends to the wheel spindles,

303-05.

install and tighten the nuts.

Steering Gear — I6

Removal
1. Raise the hood and raise the vehicle supporting it

under the body side rails.

2. Place a drain pan under the steering gear.
3. Disconnect the pump to steering gear hydraulic

lines at the gear using a six point tube nut

wrench.

4. Remove the bolt from the clamp at the lower end

of the intermediate shaft. Slide the intermediate

shaft upwards until it is clear of the steering gear

valve splines.

3. Refit the catalytic convertor assembly.
4. Centralise the steering gear and align the

intermediate shaft with the steering gear valve

and slide the shaft yoke onto the valve. Install and

tighten the lower clamp bolt.

5. Connect the hydraulic lines to the steering gear

and tighten the unions with a six point tube nut

wrench.

6. Remove drain pan and lower the vehicle.
7. Top up the pump reservoir with the specified fluid

and bleed the system as per manual.

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211-02-24 Power

Steering 211-02-24

REMOVAL AND INSTALLATION (Continued)

10. Top up the pump reservoir with the specified fluid

Steering Gear — V8

and bleed the system as per manual.

Removal

Steering Gear Bushing and Sleeve

1. Raise the hood and raise the vehicle supporting it

under the body side rails.

Removal

2. Place a drain pan under the steering gear.

1. Remove the steering gear from the vehicle. Refer

3. Disconnect the pump to steering gear hydraulic

to your dealership service manual.

lines at the gear using a standard 12 point ring

2. Remove the steering gear bushing sleeve from

spanner (double hex).

the steering gear bushings.

4. Remove the bolt from the clamp at the lower end

3. Remove the steering gear bushings from the rack

of the intermediate shaft. Slide the intermediate

and pinion housing.

shaft upwards until it is clear of the steering gear

valve splines.

5. Loosen the tie rod end stud nuts and free the tie

rod end stud tapers in the wheel spindles.

Remove the nuts and detach the tie rod ends

from the spindles.

6. Remove both catalytic converter assemblies as

outlined in the relevant section.

7. AUTOMATIC ONLY - Remove the torque

convertor inspection cover as outlined in the

relevant section.

8. Loosen the two nuts securing the steering gear to

the cross-member .

9. Draw the steering gear back away from the

Installation

cross-member to access both the steering gears

left and right transfer tubes.

1. Install the steering gear bushings into the rack

and pinion housing.

10. Remove the left and right transfer tubes from the

NOTE: Do not apply any type of lubricant or

steering gear.

grease to the steering gear bushings or the

11. Remove the two nuts securing the steering gear

steering gear bushing sleeve.

to the cross-member and remove the gear from

the vehicle.

2. Align the steering gear bushing sleeve and install

into the steering gear bushings. The steering gear

Installation

bushings must be flush with the steering gear

1. Position the steering gear assembly on the

bushing sleeve.

cross-member.

NOTE: The steering gear bushing sleeve must be

2. Install but only tighten the securing nuts slightly

properly aligned.

allowing the steering gear to rest safely away from

the cross-member.

3. Install both left and right transfer tubes into the

steering gear, tighten the securing nuts.

4. AUTOMATIC ONLY - Install the torque convertor

inspection cover as outlined in the relevant

section.

5. Connect the tie rod ends to the wheel spindles,

install and tighten the nuts.

6. Refit the catalytic convertor assemblies.
7. Centralise the steering gear and align the

intermediate shaft with the steering gear valve

and slide the shaft yoke onto the valve. Install and

tighten the lower clamp bolt.

8. Connect the hydraulic lines to the steering gear

3. Install the steering gear into the vehicle. Refer to

and tighten the unions with a 12 point ring

your dealership service manual.

spanner (double hex).

9. Remove drain pan and lower the vehicle.

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