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HOMESERVICE MANUALSFORD2004ECONOLINE E150, VAN CARGO, 4.6 WREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 495 (POWER STEERING SYSTEM)DISASSEMBLY AND ASSEMBLYSTEERING GEARASSEMBLY
2004 Ford Econoline E150, Van Cargo, 4.6 W

Steering Gear: Assembly

2004 Ford Econoline E150, Van Cargo, 4.6 WSECTION Assembly
WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
  1. Lubricate the sector shaft seal bore.
    • Use multi-purpose grease.
      Fig 1: Lubricating Sector Shaft Seal Bore
      G03884828Courtesy of FORD MOTOR CO.
  2. Using the special tool, install the sector shaft seal.
    • Lubricate the sector shaft seal, using multi-purpose grease.
      Fig 2: Installing Sector Shaft Seal
      G03884832Courtesy of FORD MOTOR CO.
  3. Install the spacer.
    Fig 3: Installing Spacer
    G03884830Courtesy of FORD MOTOR CO.
  4. Install the snap ring.
    Fig 4: Installing Snap Ring
    G03905025Courtesy of FORD MOTOR CO.
    5. NOTE: Place the steering gear sector shaft dust seal on the Sector Shaft Seal Replacer so the raised lip is toward the tool.
  5. Using the special tool, install the sector shaft dust seal.
    • Lubricate the steering gear sector shaft dust seal using multi-purpose grease.
      Fig 5: Installing Sector Shaft Dust Seal
      G03884832Courtesy of FORD MOTOR CO.
  6. Remove the steering gear housing from the holding fixture.
  7. Position the input shaft bearing in the valve housing and use the special tool and a press to seat the bearing.
    Fig 6: Pressing Seat To Bearing
    G03884833Courtesy of FORD MOTOR CO.
  8. Using the special tool and a press, seat the power steering gear input shaft seal.
    Fig 7: Identifying Power Steering Gear Input Shaft Seal
    G03884833Courtesy of FORD MOTOR CO.
  9. Install the input shaft snap ring.
    Fig 8: Installing Input Shaft Snap Ring
    G03884835Courtesy of FORD MOTOR CO.
  10. Using the special tool, install the power steering gear input shaft seal dust seal.
    Fig 9: Installing Power Steering Gear Input Shaft Seal Dust Seal
    G03884836Courtesy of FORD MOTOR CO.
  11. Mount the valve housing to the special tool.
    Fig 10: Mounting Valve Housing To Special Tool
    G03884837Courtesy of FORD MOTOR CO.
  12. Install the power steering gear input shaft and control into the valve housing.
    Fig 11: Installing Power Steering Gear Input Shaft And Control Into Valve Housing
    G03884838Courtesy of FORD MOTOR CO.
  13. Position the power steering gear race nut into the valve housing.
    Fig 12: Positioning Power Steering Gear Race Nut Into Valve Housing
    G03884839Courtesy of FORD MOTOR CO.
  14. Using the special tool, tighten the race nut.
    Fig 13: Tightening Race Nut
    G03884840Courtesy of FORD MOTOR CO.
  15. Install the setscrew.
    Fig 14: Installing Setscrew
    G03884841Courtesy of FORD MOTOR CO.
  16. Remove the valve housing from the holding fixture and position the piston on the worm gear.
    Fig 15: Removing Valve Housing From Holding Fixture And Positioning Piston On Worm Gear
    G03884842Courtesy of FORD MOTOR CO.
    17. WARNING: Hold the ball return guides until the cap or clip is reinstalled. Failure to hold the guides will result in a trapped ball or balls, which can cause a vehicle accident. If the ball guides become unseated at any time, remove all the balls and repeat the procedure. Failure to follow these instructions may result in personal injury.
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Stop DIY work and contact a certified mechanic immediately if any of the following apply:

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  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
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