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HOMESERVICE MANUALSFORD1996CUTAWAY E250, E4ODREPAIR AND DIAGNOSIS (SINGLE PAGE)STEERINGMANUAL STEERINGSTEERING SYSTEM - INTEGRAL POWER STEERINGOVERHAULSTEERING GEAR UNITDISASSEMBLY
1996 Ford Cutaway E250, E4OD

Steering Gear Unit: Disassembly

1996 Ford Cutaway E250, E4ODSECTION Disassembly
  1. Remove steering gear unit. See STEERING GEAR  under REMOVAL & INSTALLATION. Drain steering gear by holding gear unit upside down and turning input shaft several times. Mount gear in a soft-jawed vise with sector shaft cover upward. See Figure.
  2. Remove lock nut from sector shaft adjusting screw. To center steering gear, turn input shaft lock to lock, counting number of turns and divide by 2. From lock, turn shaft number of turns required to center sector shaft. If properly centered, flat surface on input shaft should be facing down.
  3. Remove sector shaft cover bolts. Tap lower end of sector shaft with a soft-faced hammer to loosen shaft in housing bore. Lift shaft and cover assembly from housing. Discard cover "O" ring. Remove sector shaft adjusting screw from cover.
  4. Remove control valve housing attaching bolts and identification tag. Lift control valve housing and piston assembly from gear housing. Discard housing gasket. Remove Teflon ring and "O" ring from piston assembly. See Fig 1.
  5. Hold piston assembly over a clean container. Remove ball guide clamp screws, letting guide tubes and balls fall into container. Rotate input shaft lock to lock until all 27-29 balls fall from piston into container. Remove worm and valve assembly from piston. Ensure all balls have been removed from piston.
  6. Install valve body assembly in bench-mounted Holding Fixture (T57L-500-B) or soft-jawed vise. Loosen Allen head race nut screw from valve housing. Remove worm bearing race nut using Wrench (T66P-3553-B) and Valve Housing-To-Piston Spacer (T66P-3553-C). See Fig 2. Carefully slide input shaft and worm and valve assembly out of control valve housing.
Fig 1: Exploded View Of Piston & Control Valve Housing
G92E22289Courtesy of FORD MOTOR CO.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.