steering FORD MUSTANG 2003 Workshop Manual

REMOVAL AND INSTALLATION
Hose
Removal and Installation
CAUTION: While servicing the power steering system, make sure to plug all open hoses,
line fittings, and fluid ports to prevent the entry of contaminants or premature failure of the
power steering components can result.
1. Refer to the System View illustration in Description and Operation for the hose routing and retention points.
2. When connecting a fitting with a seal ring, a new seal ring must be installed. zThe special tool is used to install the return line connector seal and the pressure line
connector seal.
3. Fill, purge and leak check the system. For additional information, refer to Section 211 - 00 .
SECTION 211-
02: Power Steering 2003 Mustang Workshop Manual Special Tool(s)
Installer Set, Teflon Seal
211-
D027 (D90P-3517- A) or
equivalent Klj . 1 ba
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REMOVAL AND INSTALLATION
Cooler —
Fluid
Removal 1. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
2. Disconnect the power steering hoses.
3. Remove the bolt and routing bracket.
4. Remove the bolts and the power steering fluid cooler.
Installation 1. To install, reverse the removal procedure.
2. Fill and leak check the power steering system. For additional information, refer to Section 211 -SECTION 211-
02: Power Steering 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL AND INSTALLATION
Gear
Removal
1. Turn the steering wheel as necessary to position the wheels in the straight- ahead position. Do
not lock the steering column.
2. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
3. Remove the front wheels and tires. For additional information, refer to Section 204 - 04 .
4. Remove the cotter pin and nut. Discard the cotter pin.
5. Using the special tool, disconnect the tie- rod end.
SECTION 211-
02: Power Steering 2003 Mustang Workshop Manual Special Tool(s)
Teflon Seal Replacer Set
211-
D027 (D90P-3517- A) or
Equivalent Tie Rod End Remover
211-
001 (TOOL- 3290-D) Klj . 1 ba
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6. Rotate the steering column intermediate shaft as necessary to access the pinch bolt. Remove
and discard the pinch bolt.
7. Lower the vehicle.
8. Turn the steering wheel back to the straight- ahead position. Turn the ignition key to the locked
position.
9. CAUTION: Do not rotate the steering wheel when the lower steering column shaft is
disconnected, or damage to the air bag sliding contact will result.
Disconnect the steering column intermediate shaft coupling (3A525).
10. Remove the nuts, washers and bolts. Position the steering gear (3504) forward.
11. Disconnect the power steering hoses. Remove and discard the seal rings. zPlug or cap the power steering hoses and steering gear ports to prevent damage and the
entry of foreign material. Klj . 2 ba
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12. Remove the steering gear.
Installation 1. To install, reverse the removal procedure. zUsing the special tool, install a new seal ring.
z Install a new pinch bolt. Klj . 3 ba
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2. Fill and leak check the power steering system. For additional information, refer to
Section 211 -
00 . Klj . 4 ba
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DISASSEMBLY AND ASSEMBLY
Gear
Disassembly
NOTE:
The steering gear is serviceable as either a long or short rack assembly. This procedure covers
the removal and installation of the components not supplied with a short rack assembly. On short rack
assembly only the front wheel spindle tie- rods and front suspension steering ball stud dust seals are
serviced separately.
All steering gears
1. Remove the steering gear mounting bracket housing insulators. zDiscard worn or damaged steering gear mounting bracket housing insulators.
SECTION 211-
02: Power Steering 2003 Mustang Workshop Manual Special Tool(s)
Head Mounting Fixture
303-
D041 (D83L-500- B1) or
Equivalent Inner Tie Rod Socket Tool
211-
D025 (D90P-3290- A) or
Equivalent Steering Gear Holding Fixture
211-
D011 (D87P-3504- B) or
Equivalent
Material Item Specification
Multi-
Purpose Grease
XG- 4 ESR-
M1C159-
A Silicone Brake Caliper Grease
and Dielectric Compound
D7AZ-
19A331- A ESE-
M1C171-
A Klj . 1 ba
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2. Install the steering gear into the special tools.
3. Clean the exterior of the steering gear with solvent. If necessary, drain any excess power
steering fluid.
4. Inspect the steering gear housing for cracks and other damage. If necessary, install a new steering gear.
5. Verify the power steering gear input shaft bearing rotates freely. If necessary, install a new steering gear.
6. Place an alignment mark on the tie- rod ends, nuts and front wheel spindle tie- rods. Remove the
tie- rod ends and nuts.
7. CAUTION: Use care not to damage the front suspension steering ball stud dust
seals. If the front suspension steering ball stud dust seals are damaged, this will allow
contamination into the steering gear and cause leakage.
Remove the clamps and the two front suspension steering ball stud dust seals.
zDiscard any clamps that are damaged or excessively corroded.
z Discard any front suspension steering ball stud dust seals that are damaged. Klj . 2 ba
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8.
CAUTION: Place the steering gear at the center position. Use a crowfoot on the flat
of the rack gear to resist rotation and prevent damage to the steering gear during
removal and installation of the front wheel spindle tie- rods.
Place the steering gear at the center position. Install a crowfoot on the flat of the steering gear.
Using the special tool remove the front wheel spindle tie- rods.
Steering gears equipped with travel restrictors 9. NOTE: Some steering gears may contain one or two rack travel restrictors on each side of the
steering gear. The restrictors are split washers and can be removed if necessary.
Remove the travel restrictors.
zDiscard any travel restrictors that are heavily worn.
All steering gears 10. Remove the steering gear from the special tools.
Assembly
All steering gears 1. Install the steering gear in the special tools.
Steering gears equipped with travel restrictors 2. Install the travel restrictors. zInstall new travel restrictors as necessary. All steering gears Klj . 3 ba
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3.
CAUTION: Place the steering gear at the center position. Use a crowfoot on the flat
of the rack gear to resist rotation and prevent damage to the steering gear during
removal and installation of the front wheel spindle tie- rods.
Place the steering gear at the center position. Install a crowfoot on the flat of the steering gear.
Using the special tool install the front wheel spindle tie- rods.
4. Thoroughly clean the steering gear of any foreign material.
5. CAUTION: Use care not to damage the front suspension steering ball stud dust
seals. If the front suspension steering ball stud dust seals are damaged, this will allow
contamination into the steering gear and cause leakage.
Install the front suspension steering ball stud dust seals and clamps.
zPosition the front suspension steering ball stud seals and steering gear rack tubes as
shown.
z Install new front suspension steering ball stud dust seals and clamps as necessary.
z To prevent the front suspension steering ball stud dust seals from twisting during toe
adjustment, apply grease to the groove in the front wheel spindle tie- rods and uniformly
to the inner- diameter of the front suspension steering ball stud dust seals. Klj . 4 ba
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