Overhaul
Steering Gear - F-250, F-350Special Tool(s):
Material:
CAUTION: While repairing the power steering system, care should be taken to prevent the entry of contaminants, or premature failure of the power steering components may result.
NOTE: The steering gear piston assembly cannot be repaired or installed separately.
1. Remove the steering gear.
Disassembly
1. CAUTION: Use a soft-jawed vise to secure the steering gear or damage to the steering gear housing may occur.
Secure the steering gear in a soft-jawed vise. Use protective caps on the vise jaws.
2. Rotate the steering gear input shaft from stop-to-stop and record the number of rotations.
^ Rotate the input shaft in the opposite direction 1/2 of the total rotations recorded to center the gear.
3. Remove the meshload adjusting screw jam nut.
4. Remove and discard the meshload adjusting screw locknut.
5. Remove the 4 steering gear sector shaft housing cover bolts.
6. CAUTION: If there is evidence of damage, scratches or wear to the steering gear/sector shaft housing sealing area, a new steering gear must be installed or a fluid leak may occur.
Rotate the meshload adjusting screw clockwise until the sector shaft housing cover is separated from the adjuster screw.
^ Inspect the sector shaft housing cover bore.
7. Remove and discard the sector shaft housing cover seal.
8. CAUTION: If there is evidence of damage, scratches or wear to the sector shaft, a new steering gear assembly must be installed or a fluid leak may occur.
Using a soft mallet, gently tap on the lower end of the sector shaft and remove the sector shaft.
9. Remove the 4 valve housing bolts.
10. Remove the valve housing and piston assembly.
11. Remove and discard the valve housing seal.
12. Place the valve housing in the special tool and remove the worm thrust bearing retainer ring setscrew.
^ Discard the setscrew.
13. Using the special tool, remove the worm thrust bearing retainer ring.
14. Remove the input shaft and control from the valve housing.
15. Rotate the holding fixture 180 degrees.
16. CAUTION: Do not allow the screwdriver to make contact with the valve housing bore, or damage to the sealing area may occur, causing a fluid leak.
Using a screwdriver, remove and discard the input shaft dust seal.
17. Remove and discard the input shaft seal snap ring.
18. Rotate the holding fixture 180 degrees.
19. Using the special tool, remove the input shaft bearing and input shaft seal.
^ Discard the input shaft seal.
20. Remove the valve housing from the holding fixture.
21. Reposition the steering gear in the vise to access the sector shaft seals.
22. CAUTION: Do not allow the screwdriver to make contact with the sector shaft seal bore, or damage to the sealing area may occur, causing a fluid leak.
Using a screwdriver, remove and discard the sector shaft dust seal.
23. Remove the sector shaft seal snap ring and spacer.
^ Discard the snap ring.
24. CAUTION: Do not allow the seal puller to make contact with the sector shaft seal bore, or damage to the sealing area may occur, causing a fluid leak.
NOTE: The steering gear sector shaft bearing is not serviceable.
Using a suitable seal puller, remove and discard the sector shaft seal.
^ Inspect the sector shaft seal bore.
25. Remove and discard the valve housing-to-gear housing O-ring seal.
Assembly
1. Lubricate the sector shaft seal bore with multi-purpose grease.
2. NOTE: Lubricate the sector shaft seal and spacer with multi-purpose grease.
Position the new sector shaft seal and the spacer on the special tool, and using a press, install the new sector shaft seal and the spacer.
^ Press the seal and spacer until the spacer is slightly below the snap ring groove.
3. Install the new sector shaft seal snap ring.
4. NOTE: Place the sector shaft dust seal on the special tool so the raised lip is toward the tool.
Position the new sector shaft dust seal on the special tool, and using the press, install the new sector shaft dust seal.
^ Lubricate the steering gear sector shaft dust seal with multi-purpose grease.
5. Position the input shaft bearing in the valve housing and use the press and the special tool to seat the bearing.
6. Using the press and the special tool, install the new input shaft seal.
7. Install the new input shaft housing snap ring.
^ Lubricate the top of the input shaft seal with multi-purpose grease.
8. NOTE: Place the input shaft dust seal on the special tool so the raised lip is toward the tool.
Using the special tool, install the new input shaft dust seal.
9. Mount the valve housing to the special tool.
10. Install the input shaft and control into the valve housing.
11. Position the steering gear worm thrust bearing retainer ring into the valve housing.
12. Using the special tool, tighten the worm thrust bearing retainer ring.
^ Tighten to 99 Nm (73 ft. lbs.).
13. Install the new worm thrust bearing retainer ring setscrew.
^ Tighten to 2 Nm (18 inch lbs.).
14. Secure the steering gear housing in the soft-jawed vice.
15. Install the new valve housing-to-gear housing O-ring seal.
16. Install the new valve housing seal.
17. Lubricate the piston seal with multi-purpose grease.
18. Install the piston assembly into the steering gear housing.
19. Rotate the input shaft from stop-to-stop and record the number of rotations.
^ Rotate the input shaft 1/2 of the total rotations to align the piston for correct sector shaft installation.
20. Install the sector shaft into the steering gear housing.
21. Apply Threadlock(R) and install the 4 valve housing bolts.
^ Tighten to 54 Nm (40 ft. lbs.).
22. Install a new O-ring on the sector shaft housing cover and lubricate with multi-purpose grease.
23. Place the sector shaft housing on the meshload adjusting screw and rotate the adjusting screw counterclockwise until the sector shaft housing cover is drawn into the steering gear housing and the adjusting screw bottoms out.
24. Using a soft mallet, gently tap on the meshload adjusting screw to fully seat the sector shaft housing.
25. Apply Threadlock(R) and loosely install the 4 sector shaft housing cover bolts.
26. CAUTION: Do not exceed 30 Nm (22 ft. lbs.) when applying pressure to the sector shaft housing, or damage to the housing may occur.
Install an original steering gear mounting bolt into the steering gear housing, applying pressure to the side of the sector shaft housing.
^ Tighten the steering gear mounting bolt to 25 Nm (18 ft. lbs.).
27. Tighten the 4 sector shaft housing cover bolts to 68 Nm (50 ft. lbs.).
^ Remove the steering gear mounting bolt.
28. CAUTION: new meshload adjusting screw locknut must be installed or a fluid leak at the meshload adjusting screw may occur.
NOTE: The meshload adjusting screw locknut will be tightened during the steering gear meshload adjustment. Do not tighten the locknut at this time.
Loosely install the meshload adjusting screw locknut.
29. Rotate the input shaft to the left stop and then back-off approximately 45 degrees.
30. Using a dial or digital torque wrench and a crows foot wrench, slowly and evenly rotate the input shaft clockwise 1/2 turn (180 degrees), starting from the 45 degree position. This torque reading is the preload torque.
^ Record the preload torque.
^ The preload torque must be within 0.34-1.36 Nm (3-12 inch lbs.).
31. Rotate the input shaft to its center of travel (approximately 1.5 turns from either stop). Place the torque wrench on the input shaft with the handle in the vertical position. Rotate the torque wrench slowly and evenly 1/4 turn (90 degrees) from each side of center. This torque reading is the on-center torque.
^ Record the torque measured on or near center.
32. NOTE: The on-center torque must be 1.01-1.47 Nm (9-13 inch lbs.) greater than preload torque without exceeding a total of 2.32 Nm (20.5 inch lbs.). The on-center torque minus the preload torque is the meshload torque.
If necessary, carry out the following steps to adjust the on-center torque.
33. NOTE: Rotate the meshload adjusting screw clockwise to increase the on-center torque and counterclockwise to decrease the on-center torque.
Rotate the meshload adjusting screw until the on-center and meshload torque readings fall within the specified values.
34. While holding the meshload adjusting screw, tighten the meshload adjusting screw locknut to 31 Nm (23 ft. lbs.).
35. Install the meshload adjusting screw jam nut.
^ Tighten to 17 Nm (13 ft. lbs.).
36. Install the steering gear.