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HOMESERVICE MANUALSMERCURY1994CAPRI XR2, AUTOMATICREPAIR AND DIAGNOSIS (SINGLE PAGE)STEERINGPOWER STEERINGSTEERING SYSTEM - POWER RACK & PINIONOVERHAULSTEERING GEARREASSEMBLY
1994 Mercury Capri XR2, Automatic

Steering Gear: Reassembly

1994 Mercury Capri XR2, AutomaticSECTION Reassembly
  1. Install NEW "O" ring onto spool valve. Apply Grease (C1AZ-19590-E) to pivot lever hole in spool valve and to pivot lever hole in valve body. Apply Premium Power Steering Fluid (E6AZ-19582-AA) to remainder of spool valve. Install spool valve. Apply grease to pivot lever/collar and to bushing.
  2. Install pivot lever into spool valve housing. Ensure longer end of pivot lever/collar is seated in spool valve. Install end plug into spool valve housing. Apply power steering fluid to inner guide. Install inner guide and inner rack seal into rack housing with Inner Rack Seal Remover (T87C-3504-A).
  3. Apply grease to rack teeth, but DO NOT plug rack air hole with grease. Install Rack Oil Seal Protector (D83P-3504-K). Install NEW rack piston seal onto rack with Piston Seal Replacer (T81P-3504-L), Pusher (T75L-3517-A2) and Sizer(T81P-3504-K).
  4. Apply power steering fluid to rack piston. Cover rack with electrical tape. Coat inside of rack housing with power steering fluid. Carefully slide rack into housing, as far as it will go. Remove rack seal protector. Install NEW bushing into outer bulkhead with Pinion Cover Installer (T18P-3504-Y).
  5. Install NEW sealing ring, oil seal and "O" rings at bulkhead end of rack housing. Lubricate all parts with power steering fluid before installation. Wrap outer bulkhead with towel, then install with pipe wrench. Stake bulkhead to rack housing with punch. Install lower bearing onto pinion shaft. Install and tighten retaining nut to 29-36 ft. lbs. (39-49 N.m).
  6. Stake nut to pinion shaft. Install pinion shaft into housing with rack extending 2.70" (68.7 mm) from housing on pinion shaft end. Ensure notch on pinion shaft spline is located 60 degrees from horizontal center. See Fig 1 .
    Fig 1: Installing Pinion Shaft (Capri)
    G92E00707Courtesy of FORD MOTOR CO.
  7. Grease upper pinion bearing. Install into housing with Upper Pinion Seal Replacer (T78P-3504-D). Tighten pinion bearing cover to 44-80 INCH lbs. (5-9 N.m), then loosen 10-20 degrees. Tighten lock nut to 29-36 ft. lbs. (39-49 N.m).
  8. Using a NEW gasket, install valve body. Install yoke, spring, yoke plug and lock nut. Tighten cover to 40-49 INCH lbs. (4.5-5.5 N.m). Loosen cover 45 degrees. Measure pinion rotating torque with INCH-lb. torque wrench and Pinion Adapter (T87C-3504-C).
  9. Pinion rotating torque should be 5.3-13.3 INCH lbs. (0.6-1.5 N.m). If pinion rotating torque is not within specification, loosen or tighten adjuster plug as necessary. After pinion rotating torque is adjusted to specification, tighten lock nut to 29-36 ft. lbs. (39-49 N.m). Mount steering gear in soft-jawed vise. Install damper ring, washer and tie rod.
  10. Tighten tie rod to 44-59 ft. lbs. (60-80 N.m). Stake tab washer in 2 places. Position damper ring into washer. Install remaining damper ring, washer and tie rod. Install dust boots.
  11. Install tie rod ends, aligning marks made during disassembly. Wrap electrical tape around and apply grease to pinion shaft. Apply grease to lips of pinion shaft seal. Install pinion shaft seal with Pinion Bearing Replacer (T78P-3504-D).
  12. Remove tape from pinion shaft. Install support brackets and rubber bushings. Install hydraulic lines and NEW copper sealing rings onto each banjo fitting.
RENDER: 1.0x

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