Tie Rod End: Service and Repair

Fig. 2 Exploded View Of Ford Manual Steering Gear:

Disassembly

1. Disable airbag system as described in MAINTENANCE PROCEDURES/AIRBAG SYSTEM DISARMING if equipped, then clean exterior of gear assembly.
2. Loosen jam nuts and remove tie rod ends and jam nuts, Fig. 2.
3. Remove bellows clamps and the small (outer) tie rod clamps. Discard bellows clamps.
4. Remove the bellows.
5. Cycle gear to full right turn to expose rack teeth. Mount rack teeth in soft jawed vise to remove either or both tie rod ends.
6. Remove tie rod ends by turning ball socket with pipe wrench.
7. Check rack for corrosion and contamination. If either is present, the gear must be completely overhauled or replaced.

Assembly

1. Cycle gear to full right turn to expose rack teeth. Mount rack teeth in a soft jawed vise.
2. Before installing tie rods, inspect ends of rack for flatness. If burrs are present, remove by lightly filing.
3. Install service tie rods and tighten to specifications.
4. Remove gear assembly from vise.
5. Support ball socket, and stake to rack using a stake punch. Center of stake punch should be approximately 1.5 mm (.06 inch) away from rack end. Perform visual inspection to verify displacement of metal into rack slot.
6. Replenish any grease that may have been removed with fresh grease by applying it to the rack teeth. Coat remainder of rack (both ends) with a light film of grease. Use specified steering gear lubricant.
7. Install bellows and clamps. Ensure small diameter of bellows is in the tie rod groove.
8. Install jam nuts and tie rod end, then rearm air bag system, if equipped.