Ford Falcon. Manual — part 91
211-02-17 Power
Steering 211-02-17
REMOVAL AND INSTALLATION
4. Install the cylinder line assemblies to the gear
Steering Gear Cylinder Pipe and O —
assembly.
Ring Seals
NOTE: Tighten the valve end fittings to 16.9 Nm
(12.6 lb. ft.)
Removal
Tighten the cylinder end fittings to 27 Nm (20 lb.
1. Remove the steering gear from the vehicle. Refer
ft.)
to your dealership service manual.
2. Loosen both cylinder line fittings on the cylinder
Steering Gear Spool Shaft Seals and
end of the gear assembly.
Bearings
3. Loosen both cylinder line fittings on the valve end
of the gear assembly.
Special Tool(s)
4. Remove both cylinder line assemblies from the
Valve Body Seal Protector/
rack and pinion gear assembly.
Sizer Kit
5. Remove the O-ring seals from the valve end of
J 46192
the cylinder line.
Bearing and Seal Installer
J 46193
6. Discard the O-ring seals.
Installation
1. Inspect the cylinder lines for the following items:
Cracks
Spool Shaft Seal Protector
Dents
J 46221
Damage to the threads
2. Replace the parts as needed.
3. Install the new O-ring seals to the valve end of the
cylinder lines.
Removal
1. Remove the steering gear from the vehicle. Refer
to your dealership service manual.
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211-02-18 Power
Steering 211-02-18
REMOVAL AND INSTALLATION (Continued)
2. Remove the following from the steering gear:
8. Remove and discard the metric hex nut from the
lower end of the pinion and valve assembly while
Adjuster plug
holding the spool shaft.
Adjuster spring
Rack bearing assembly with o-ring
NOTE: When performing the following procedure, do
not remove the valve assembly from the rack and
pinion gear assembly. Press the pinion end of the
valve assembly only far enough to allow removal of
the spool shaft seal and the needle bearing assembly.
9. Gently tap a pointed center punch into the
threaded end of the pinion to remove only the
following items:
Spool shaft seal
Needle bearing assembly
3. Discard the adjuster plug.
NOTE: The rack assembly must be marked inside
the rack and pinion housing to show correct
alignment. Lubrication on the rack may cause the
alignment marks to smear if the rack is moved.
4. Hold the rack firmly and mark the rack assembly
inside of the rack and pinion housing.
5. Remove the spool shaft boot.
6. Remove and discard the retaining ring from the
top of the valve housing.
7. Remove and discard the dust cover from the
bottom of the rack and pinion gear assembly.
NOTE: The spool shaft must be held in place
during the following step.
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211-02-19 Power
Steering 211-02-19
REMOVAL AND INSTALLATION (Continued)
10. Discard the spool shaft seal and the needle
1. Install the new valve body rings onto the valve
bearing assembly.
assembly using J 46192-1. Remove J 46192-1.
NOTE: Handle the valve assembly with caution.
Failure to do so may result in replacement of the
steering gear.
11. Pull the valve assembly out of the rack and pinion
housing.
12. Remove and discard the valve body rings (4) from
the valve assembly.
2. Lubricate the valve assembly with power steering
fluid.
3. Compress the valve body rings onto the valve
assembly using J 46192-2.
NOTE: The rack assembly must be aligned before
installing the valve assembly. Failure to do so will
cause the steering wheel to be out of position.
4. Align the rack assembly using the marks inside
the rack and pinion housing.
Installation
NOTE: The orientation of the pinch bolt notch on
NOTE: Handle the pinion and valve assembly with
the valve assembly must be aligned as shown.
caution. Failure to do so may result in replacement of
Failure to do so will cause the steering wheel to
the steering gear.
be out of position.
5. With J 46192-2 still on the valve assembly, install
the valve assembly into the rack and pinion
housing.
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211-02-20 Power
Steering 211-02-20
REMOVAL AND INSTALLATION (Continued)
6. Remove J 46192-2 from the rack and pinion
9. Remove J 46193 from the rack and pinion
housing.
housing.
NOTE: The bearings in the needle bearing assembly
10. Install J 46221 onto the valve spool shaft.
must be facing down when installing into gear.
11. Lubricate the new spool shaft seal with grease.
7. Install the new needle bearing assembly onto the
12. Install the spool shaft seal onto the spool shaft of
spool shaft of the valve assembly.
the valve assembly.
8. Using the smaller end of J 46193 and a rubber
13. Using the larger end of J 46193 and a rubber
mallet, gently tap the needle bearing assembly
mallet, gently tap the spool shaft seal into the rack
into the rack and pinion housing.
and pinion housing.
14. Remove J 46193 from the rack and pinion
housing.
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