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.

G37370 en

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.

G37370 en

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.

G37370 en

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.

G37370 en