Steering - Clunk/Rattle/Premature Tire Wear
Article No.93-13-2
06/23/93
^ STEERING - POWER - INNER TIE ROD IN-VEHICLE REPLACEMENT PROCEDURE
^ STEERING - POWER - LACK OF CENTER FEEL AND VEHICLE WANDER
^ TIE ROD - INNER - IN-VEHICLE REPLACEMENT PROCEDURE
^ TIRES - FRONT - PREMATURE WEAR
^ NOISE - "CLUNK" OR "RATTLE" FROM FRONT END - INNER TIE ROD IN-VEHICLE REPLACEMENT PROCEDURE
^ SHUDDER DURING DECELERATION/BRAKING
FORD:
1986-93 MUSTANG, TAURUS, TEMPO, THUNDERBIRD
1991-93 ESCORT
LINCOLN-MERCURY:
1986-92 MARK VII
1986-93 CONTINENTAL, COUGAR, SABLE, TOPAZ
1991-93 TRACER
1993 MARK VIII
LIGHT TRUCK:
1986-93 AEROSTAR
ISSUE:
An inner tie rod in-vehicle replacement procedure has been developed for the subject vehicles. The inner tie rod is worn if it exhibits any lash or axial free-play. Worn inner tie rods may exhibit some of the following symptoms:
^ "Clunk" or "rattle" noise in the front end during vehicle deceleration or cruise operation modes when going over small bumps, etc.
^ Front tire wear
^ Inconsistent alignment toe setting by the service specialist
^ Lack of center feel
^ Vehicle wanders
^ Vehicle shudder during decel/braking
ACTION:
If service is required, use the following service procedure to install the inner tie rod assemblies.
CAUTION:
SERVICE AND REPAIR PROCEDURES DESCRIBED IN THE SERVICE MANUALS ARE TO BE MODIFIED PER THIS TSB ARTICLE. ALL SERVICE MANUAL NOTES, CAUTIONS AND WARNINGS SHOULD BE OBSERVED. THESE INNER TIE ROD PARTS MUST BE INSTALLED BY A QUALIFIED TECHNICIAN, OTHERWISE AN UNSAFE VEHICLE AND PERSONAL INJURY MAY RESULT. SAFE AND RELIABLE INSTALLATION OF STEERING/CHASSIS PARTS REQUIRE EXPERIENCE AND TOOLS SPECIALLY DESIGNED FOR THE JOB.
DIAGNOSIS
1. Check for "clunk" noise, with the window down, engine OFF, steering column unlocked, by turning the steering wheel +/- 45~.
^ For the steel on steel type ball joints, a metal "clunk" noise may be heard.
^ For the steel on plastic type joints, refer to Step 2.
2. Raise the front of the vehicle.
a. With the tires unweighted, shake the tire from top/bottom (12/6 o'clock position) to determine wheel bearing play.
b. Compare with left/right (9/3 o'clock position) tire shake which will also include the outer and inner tie rod lash.
c. Holding the inner tie rod spindle during the latter tire shake may help verify the inner versus outer tie rod looseness. See Figure 1.
NOTE:
A MECHANICALLY LEVERAGED TOOL SUCH AS A CROWBAR MAY BE USEFUL FOR THIS DIAGNOSIS WHEN APPLIED TO THE TIRE.
3. Disregard the Service Manual pull test with two (2) to ten (10) pound pull requirement, since this may not be a reliable test.
4. The inner tie rod is worn and must be replaced if it exhibits any lash or axial free-play.
INNER TIE ROD (GEAR IN-VEHICLE) REMOVAL
1. Prepare the vehicle for servicing.
a. Unlock the steering column by turning the ignition key.
b. Engage the parking brake.
c. Raise and support the vehicle.
d. Clean any loose dirt or oil from the power steering gear and boot bellows.
2. Disconnect the outer tie rod end from the steering knuckle.
a. Loosen the jam nut and keep flush with outer tie rod.
b. Disconnect the outer tie rod from the steering knuckle. Remove the cotter pin and castle nut by using Tie Rod End Remover TOOL-3290-D or equivalent, Figure 2.
3. Mark the threads at the jam nut location.
a. Count and record the number of turns to remove the outer tie rod end from the inner tie rod. This information is useful in estimating the alignment setting.
b. Remove the jam nut from the inner tie rod spindle.
4. Remove the left and right steering gear boot bellows along with the breather tube.
NOTE
MARK THE BREATHER TUBE AND BOOT BELLOWS LARGE ID CLAMP'S ORIENTATION ON THE HOUSING FOR LATER INSTALLATION REFERENCE.
CAUTION:
USE CARE NOT TO DAMAGE THE BELLOWS.
5. FOR STEEL ON STEEL BALL JOINTS, remove the rivet or rollpin securing the inner tie rod to the steering gear rack.
a. Use a sharp chisel to gently pry up the rivet or rollpin. DO NOT CUT OFF.
b. Use side cutters or equivalent to remove the rivet, Figures 3 & 4.
CAUTION:
THE RIVET HAS A STEEL CORE WHICH WILL DEFORM THE STEERING GEAR RACK THREADS IF IT IS NOT COMPLETELY REMOVED.
c. Use Locknut Pin Remover D81P-3504-N or equivalent to remove the rollpin, Figure 5. If the rivet is not accessible, unscrew (see Step 6) the inner tie rod until it is accessible (less than 1 full turn).
6. Remove the inner tie rod from the steering gear rack using a wrench on the rack teeth in combination with the following tools as shown in Figures 6 and 7.
^ Yoke Locknut Wrench T81P-3504-G or Inner Tie Rod Socket Tool D90P-3290-A - Tempo/Topaz
^ Nut Wrench T74P-3504-U - Aerostar, Thunderbird, Cougar, Continental, Mark VII & Mark VIII, Mustang, Taurus and Sable An adjustable wrench may be used on the rack teeth.
CAUTION:
HAVE STEERING GEAR AT OR NEAR THE FULL TURN (LOCK) POSITION. USE A WRENCH ON THE RACK TEETH (FLAT) TO RESIST RACK ROTATION AND PREVENT DAMAGE TO THE PINION DURING REMOVAL AND INSTALLATION. ALLOWING THE RACK AND PINION TO INTERNALLY RESIST TIGHTENING OR LOOSENING TORQUES MAY CAUSE DAMAGE TO THE STEERING GEAR.
7. Clean the following components.
^ The steering gear housing OD interface and boot bellows ID (each end).
^ The steering gear housing ID and rack as required.
^ All parts to be inspected and replaced if necessary. Make sure the rack threads are clean and dry.
CAUTION:
THOROUGHLY REMOVE ANY ABRASIVE MATERIAL. THESE CONTAMINANTS ARE EXTREMELY HARMFUL TO THE HIGH PRESSURE STEERING GEAR RACK SEAL INTERFACE.
INSTALLATION
1. Refer to the Parts Block in this article for correct parts usage.
2. Replenish any grease (C3AZ-19578-A) which may have been removed from the rack teeth.
3. For replacement plastic on steel ball joints that do not have the rivet feature, proceed as follows:
a. Clean any contamination, dirt or oil from the rack threads and wipe dry.
CAUTION:
THOROUGHLY REMOVE ANY ABRASIVE MATERIAL. THESE CONTAMINANTS ARE EXTREMELY HARMFUL TO THE HIGH PRESSURE STEERING GEAR RACK SEAL INTERFACE.
b. Apply locking compound (E2FZ-19544-B) (Loctite 262 or equivalent) to the steering gear rack threads. The thread locking compound will set sufficiently so that the vehicle may be driven when the remove and replace procedure is complete, including the alignment toe.
4. Hold the rack securely as shown in Figure 7. If both inner tie rods are replaced, tighten each inner tie rod separately.
^ For Mustang, Mark, Thunderbird, Cougar, Taurus, Sable, Continental, Aerostar, the torque specification is 55-60 lb.ft. (75-81 N-m).
^ For Tempo/Topaz, the torque specification is 40-50 lb.ft. (54-68 N-m).
5. For ball joints that use the rivet (N804152-S), install rivet (which replaces the rollpin) using channel locks or equivalent, Figure 8.
6. Check the inner tie rod function by moving the tie rod spindle. Handshake in various directions.
7. Apply steering gear grease (C3AZ-19578-A) (ESW-M1CC877-A) to the inner tie rod groove where the boot bellows attach with a clamp to the inner tie rod. This allows for toe-in adjustments without twisting the bellows.
8. Apply steering gear grease (C3AZ-19578-A) (ESW-M1CC877-A) to the steering gear housing OD/boot bellows' large OD interface. This layer of grease will help keep water and contamination from entering the ball joint and rack sealing sur faces.
9. Install the boot bellows and breather tube.
a. Check to see that the boot bellows are properly positioned over the steering gear housing bead at the large ID, and are in the tie rod groove at the small ID.
b. Check to see that the boot bellows are not twisted and that the vent tube is securely inserted into the vent nipple AT BOTH BOOTS.
c. At the boot bellows/housing large ID, install screw type (hose) clamps and position screw axis as shown in Figure 9. Tighten screw to 1.7-2.5 lb.ft. (2.3-3.4 N-m).
CAUTION:
DO NOT USE TIE STRAPS TO SECURE BOOT BELLOWS TO STEERING GEAR HOUSING.
d. At the boot bellows/inner tie rod small ID, install clamp.
10. Install the jam nut and apply Disc Brake Caliper Slide Grease (D7AZ-19590-A) or equivalent, to the inner tie rod threads.
11. Install the outer tie rod to the inner tie rod. Count the number of turns recorded earlier. This approximates the previous alignment toe setting.
12. Tighten the jam nut against the outer tie rod end.
^ For Mustang, Mark, Thunderbird, Cougar, Taurus, Sable, Continental, Aerostar, the torque specification is 35-50 lb.ft. (47-68 N-m).
^ For Tempo/Topaz, the torque specification is 42-50 lb.ft. (57-68 N-m).
13. Connect the outer tie rod to the steering knuckle.
a. Tighten the castle nut at the steering knuckle to a minimum 27 lb.ft. (36 N-m).
b. Continue tightening direction until the hole allows installation of a new cotter pin.
^ For Mustang, Mark, Thunderbird, Cougar, Taurus, Sable, Continental, Aerostar, the torque specification is 35-47 lb.ft. (47-64 N-m).
^ For Tempo/Topaz, the torque specification is 27-32 lb.ft. (36-43 N-m).
14. Align the front end to specification. Refer to the appropriate Vehicle Service Manual for service details.
OTHER APPLICABLE ARTICLES: 90-11-3
WARRANTY STATUS:
Eligible Under Bumper To Bumper For 1991 Lincolns And All 1992/93 Models, Basic Warranty Coverage For All Other Models
OPERATION DESCRIPTION TIME
931302A Install Both Tie Rod End 1.5 Hrs.
Assemblies - Escort/Tracer
931302B Install Both Tie Rod End 1.9 Hrs.
Assemblies - Tempo/Topaz
931302C Install Both Tie Rod End 1.6 Hrs.
Assemblies - Taurus/Sable
931302D Install Both Tie Rod End 1.6 Hrs.
Assemblies - Continental
931302E Install Both Tie Rod End 1.5 Hrs.
Assemblies - Thunderbird/Cougar/
Mark/Mustang
931302F Install Both Tie Rod End 1.7 Hrs.
Assemblies - Aerostar
DEALER CODING
BASIC PART NO. CONDITION CODE
3280 30
OASIS CODES: 303000, 390000