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Eric
Eric, Automotive Repair Shop Manager
Category: Ford
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Experience:  Automotive Repair Shop Manager, Technician
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1996 FORD AEROSTAR: 4.0L..THE STEERING RACK/PINION ASSY..I..ASSY

Resolved Question:

I HAVE A 1996 FORD AEROSTAR AWL 4.0L AND I HAVE TO REPLACE THE STEERING RACK/PINION ASSY..I NEED INSTRUCTIONS ON HOW TO GET THE OLD ASSY OUT . HOW MUCH DO I NEED TO REMOVE TO GET IT OUT...
Submitted: 6 years ago.
Category: Ford
Expert:  Eric replied 6 years ago.
  1. Hi,

Here are removal and installation instructions for the rack and pinion:

I have included both rear and all wheel drive instructions:

REAR WHEEL DRIVE VEHICLES

See Figures 2 through 10

Click image to see an enlarged view
Fig. 2: The power steering rack and pinion assembly is mounted to the front crossmember by two bolts-1991-96 rear wheel drive models

 

Click image to see an enlarged view
Fig. 3: To separate the lower intermediate shaft from the power rack and pinion, remove the pinch bolt

 

Click image to see an enlarged view
Fig. 4: 1991-96 rear wheel drive models equipped with the 4.0L engine have a power steering cooler assembly built into the return hose

 

Click image to see an enlarged view
Fig. 5: Before disconnecting the power steering fluid lines, note which line goes to which valve connection

 

Click image to see an enlarged view
Fig. 6: Cut-away view of the power steering line fittings-1991-96 models

 

Click image to see an enlarged view
Fig. 7: A tool, such as the one shown, is extremely helpful in installing a new TFE seal

 

Click image to see an enlarged view
Fig. 8: To remove the rack and pinion assembly, first disconnect the intermediate shaft from the gear, ...

 

Click image to see an enlarged view
Fig. 9: ... detach the power steering line clips and attached lines, then ...

 

Click image to see an enlarged view
Fig. 10: ... remove the steering gear-to-crossmember bolts

 

  1. Turn the ignition key to the OFF position.

  2. On vehicles equipped with automatic transmissions, position the transmission selector in PARK and set the hand brake.

  3. For vehicles equipped with manual transmissions, put the gear shift lever in reverse and set the hand brake.

  4. Raise and safely support the front of the vehicle on jackstands.

  5. Remove the front wheels.

  6. Remove the lower intermediate steering column shaft retaining bolt from the steering gear.

  7. Disconnect the shaft from the steering gear.

  8. Unscrew the quick connect fitting for the power steering pressure and return lines at the rack and pinion steering gear valve housing.

Do not remove the right and left transfer tube fitting.

  1. Plug the ends of the fluid lines removed from the steering gear and the ports in the steering gear valve housing to prevent damage and entry of dirt.

  2. Remove and discard the cotter pin retaining the tie rod end.

  3. Remove the tie rod nut.

  4. Separate the steering tie rod ends from the spindle using a Pitman arm puller T64P-3590-F or equivalent.

  5. Support the steering gear and remove the two nuts, bolts, and washer assemblies retaining the steering gear to the vehicle crossmember.

  6. Remove the steering gear from the vehicle. If required, remove the front and rear insulators from the gear housing.

To install:

  1. If removed, install the insulators into the steering gear housing.

The larger end of the inner sleeve faces the rear of the vehicle and contacts the crossmember.

  1. Push the insulators in until there is no space between the lip on the insulator and edge of the steering gear housing.

  2. Position the steering gear on the crossmember. Install the nuts, bolts and washers retaining the gear to the crossmember. Tighten the nuts to 80-105 ft. lbs. (108-142 Nm).

  3. Unplug the power steering fluid lines and steering gear valve housing.

  4. If required, replace the TFE seal on the power steering pressure and return line quick connect fitting. Install a new seal as follows:

    1. Unscrew the tube nut, then replace the plastic seal washer.

    2. To facilitate assembly of the new TFE seal, a tapered shaft may be required to stretch the washer so that it may be slipped over the tube nut threads. Recommended tools are D90P-3517-A2 and D90P-3517-A3 or their equivalents.

  5. Connect the pressure and return lines to the appropriate ports on the steering gear valve housing. Tighten the fittings to 20-25 ft. lbs. (27-34 Nm).

The fittings' design allows the hoses to swivel when properly tightened. Do not attempt to eliminate looseness by over-tightening, since this can cause damage to the fittings.

  1. With the steering gear, steering wheel and front wheels in the straight ahead position, attach the tie rod ends to the spindle arms. Tighten the tie rod nuts to 52-73 ft. lbs. (70-100 Nm).

Make sure that the tie rod end ball studs are seated in the tapered spindle holes to prevent rotation while tightening the nut.

  1. If necessary, advance the tie rod nuts to the next slot, then install a new cotter pin.

  2. Position the steering column lower intermediate shaft over the steering gear input shaft spline and dust seal. Replace the pinch bolt and tighten it to 30-42 ft. lbs. (41-56 Nm).

Verify that no rotation from the straight ahead position has occurred.

  1. Install the front wheels.

  2. Lower the vehicle.

  3. Refill the power steering pump reservoir with the proper fluid. For more information, refer to Routine Maintenance .

  4. Purge air from the power steering system. Verify the absence of any unusual power steering noise.

  5. Have the front end aligned by a qualified automotive mechanic.

  6. Make sure that the power steering system operates correctly and is not leaking.

  7. Check and adjust the fluid level in the power steering pump reservoir

ALL WHEEL DRIVE VEHICLES

See Figure 11

Click image to see an enlarged view
Fig. 11: Exploded view of the front suspension system as well as the steering rack and pinion related components-1991-96 AWD models

 

  1. Start the engine, then rotate the steering gear from lock to lock (entire gear travel) and record the number of steering wheel rotations. Divide the number of steering wheel rotations by two to get the required number of turns to place the steering wheel in the centered (straight ahead) position. From one lock position, rotate the steering wheel the required number of turns to center the steering rack.

Verify that the front wheels and steering wheel are in the straight ahead position.

  1. Stop the engine, then disconnect the negative battery cable.

  2. On automatic transmissions, put the transmission selector in PARK and set the hand brake.

  3. On manual transmissions, put the gear shift lever in Reverse and set the hand brake.

  4. Remove the front hub caps.

  5. Remove the hub nut and washer.

  6. Raise the vehicle and support it safely on jackstands.

  7. Remove the front wheels.

  8. Remove the bolt retaining the lower intermediate steering column shaft to the steering gear, then disconnect the shaft from the gear.

  9. Disconnect the pressure and return lines from the steering gear valve housing. Plug the lines and ports in the steering gear valve housing to prevent the entry of dirt into the system.

  10. Remove both steering knuckles, as described earlier in this section.

  11. Remove both lower control arms, as described earlier in this section.

  12. Remove the five nuts from the forward edge of the crossmember lower plate assembly.

  13. Remove the nut from the driver side rear edge of the crossmember lower plate assembly.

  14. Remove the two bolts from the center and passenger side rear edge of the crossmember lower plate assembly.

  15. Remove the lower plate.

  16. While supporting the steering gear, remove the two bolts and spacers retaining the steering gear to the crossmember.

  17. Remove the power steering rack and pinion gear from the vehicle.

To install:

  1. If removed, install the insulators into the steering gear housing.

The larger end of the inner sleeve faces the rear of the vehicle and contacts the crossmember.

  1. Push the insulators in until there is no space between the lip on the insulator and edge of the steering gear housing.

  2. Position the steering gear on the crossmember. Install the nuts, bolts and washers retaining the gear to the crossmember. Tighten the nuts to 61-82 ft. lbs. (83-111 Nm).

  3. Install the crossmember lower plate by inserting the studs on the plate through the front edge of the crossmember.

  4. Install the two bolts in the center and passenger side of the crossmember lower plate assembly. Tighten the nuts to 35-47 ft. lbs. (47-64 Nm).

  5. Install the nut on the stud located at the driver side rear edge of the crossmember lower plate assembly. Tighten it to 22-30 ft. lbs. (30-41 Nm).

  6. Install the five nuts on the studs at the forward edge of the crossmember lower plate assembly. Tighten these nuts also to 22-30 ft. lbs. (30-41 Nm).

  7. Install both front lower control arms, as described earlier in this section.

  8. Install both steering knuckles, as described earlier in this section.

Make sure that the steering gear and front wheels are in the straight ahead position before attaching the tie rod ends to the steering knuckles. Make sure that the tie rod end ball studs are seated in the tapered spindle holes to prevent rotation while tightening the nut.

  1. Unplug the power steering fluid lines and steering gear valve housing.

  2. If required, replace the TFE seal on the power steering pressure and return line quick connect fitting. Install a new seal as follows:

    1. Unscrew the tube nut, then replace the plastic seal washer.

    2. To facilitate assembly of the new TFE seal, a tapered shaft may be required to stretch the washer so that it may be slipped over the tube nut threads. Recommended tools are D90P-3517-A2 and D90P-3517-A3 or their equivalents.

  3. Connect the pressure and return lines to the appropriate ports on the steering gear valve housing. Tighten the fittings to 20-25 ft. lbs. (27-34 Nm).

The fittings' design allows the hoses to swivel when properly tightened. Do not attempt to eliminate looseness by over-tightening, since this can cause damage to the fittings.

  1. Position the steering column lower intermediate shaft over the steering gear input shaft spline and dust seal. Replace the pinch bolt and tighten it to 30-42 ft. lbs. (41-56 Nm).

Verify that no rotation from the straight ahead position has occurred.

  1. Install the front wheels.

  2. Install the hub nuts and washers. For more information, refer to the steering knuckle procedure located earlier in this section.

  3. Install the front hub caps.

  4. Lower the vehicle.

  5. Refill the power steering pump reservoir with the proper fluid. For more information, refer to Routine Maintenance .

  6. Purge air from the power steering system. Verify the absence of any unusual power steering noise.

  7. Have the front end aligned by a qualified automotive mechanic.

  8. Make sure that the power steering system operates correctly and is not leaking.

  9. Check and adjust the fluid level in the power steering pump reservoir.

If this answer has helped please hit the ACCEPT BUTTON or ask for more help. Positive feedback is always appreciated

Eric, Automotive Repair Shop Manager
Category: Ford
Satisfied Customers: 23903
Experience: Automotive Repair Shop Manager, Technician
Eric and 11 other Ford Specialists are ready to help you
Customer: replied 6 years ago.
HOW DO I REMOVE THE CONTROL ARMS..HOW MUCH DO I HAVE TO SUPPORT THE BE CAUSE OF THE COIL SPRING..DO I REMAOVE IT AT THE TWO PIVOT POINT AND THE BOTTOM OF THE WHEEL ASSY...
Expert:  Eric replied 6 years ago.

Hi,

Here is lower control arm removal instructions, and steering knuckle removal instructions. Step #1 goes over jackstand placement and use of floorjack to lower the lower control arm after its loosened. Remember that the coil is under tremendous pressure. Always take your time follow the directions below, and use caution:

  1. Place the steering wheel and front wheels in the centered (straight ahead) position.

Anytime the steering linkage is disconnected from the spindle, the steering system must be centered before beginning the service procedure.

  1. Raise the van and support it safely with jackstands placed under the frame lifting pads. A hydraulic floor jack should be placed under the control arm to raise and lower the arm during coil spring removal. Make sure the van is supported securely on the jackstands and only work on one side at a time.

  2. Remove the front wheel/tire assemblies from the van.

  3. Remove the front stabilizer bar and end link from the lower control arm, as described earlier in this section.

  4. Remove the coil spring as described earlier in this section.

  5. Remove the bolts and nuts retaining the lower control arm to the crossmember and remove the lower control arm from the frame.

  6. If new control arm bushings or ball joints are necessary, replace the entire lower control arm assembly.

To install:

  1. Position the new lower control arm assembly to the frame crossmember, then install the retaining bolts in the proper direction as illustrated. Temporarily snug the bolts, but do not tighten to the full torque specifications yet.

  2. Inspect the lower ball joint boot and replace it if necessary.

  3. Install the coil spring as described earlier in this section.

  4. Install the stabilizer bar and end links as described earlier in this section.

  5. Install the front wheels and tires to the van.

  6. Lower the van so that it rests in the normal ride position on a level surface.

  7. Tighten the lower control arm-to-crossmember mounting bolts to 187-260 ft. lbs. (254-352 Nm) for 1986-90 models, and to 100-140 ft. lbs. (136-190 Nm) for 1991-96 models.

Knuckle and Spindle:

REMOVAL & INSTALLATION

See Figures 1 and 2

Click image to see an enlarged view
Fig. 1: Use the Pitman arm remover tool T64P-3590-F, or equivalent, to separate the tie rod from the steering knuckle

 

Click image to see an enlarged view
Fig. 2: Use the hub remover/installer T81P-1104, or equivalent, to pull the hub off of the CV-joint shaft

 

  1. Place the steering wheel and front tires in the centered (straight ahead) position.

Any time the steering linkage is disconnected from the spindle, the steering system must be centered before beginning the service procedure.

  1. Remove the front wheel covers, if necessary.

  2. Remove the center hub nut and washer.

  3. Raise the van, but do not yet support it on jackstands. Be very careful when the vehicle is lifted without being supported by jackstands.

  4. Remove the spring tension from the upper and lower control arms. Support the lower control arm with jackstands, then lower the vehicle so that the spring is partially compressed enough to take the tension out of the spring OR compress the spring using a spring compressor tool until all spring tension is removed from the control arms. Once the correct height of the van is reached, support the vehicle frame with a second set of jackstands. The lower control arm is supported with one jackstands while teh van is supported by jackstands on teh frame; this positions the lower control arm in teh proper position for knuckle and spindle service.

  5. Remove the caliper, rotor and dust shield from the spindle. For more information, refer to Brakes .

  6. Remove the cotter pin and nut retaining the tie rod end to the spindle's lower arm. Disconnect the tie rod end with a suitable Pitman arm puller such as tool T64P-3590-F or equivalent.

  7. Install a hub remover/installer T81P-1104 (A, B and C adapters are needed) or equivalent. Free the hub, bearing and knuckle assembly from the halfshaft by pushing the outer CV joint shaft until it releases from the assembly.

  8. If a spring compressor was utilized in Step 5, perform the following:

    1. Support the lower control arm with a hydraulic floor jack. Make sure the jack pad securely contacts the control arm. Remove the cotter pin, then loosen the nut retaining the spindle to the lower control arm ball joint. Disconnect the lower ball joint from the spindle using the same Pitman arm puller used in Step 5, then remove the tool and ball joint retaining nut.

    2. Slowly lower the jack under the control arm until the ball joint is disengaged from the spindle.

      ***CAUTION***Use extreme caution when lowering the lower control arm. The coil spring may quickly expand with dangerous force. Never lower the control arm quickly.

    3. Remove the bolt and nut retaining the spindle to the upper control arm ball joint, then remove the spindle from the van.

  9. If the van was lowered in order to remove the spring tension in Step 5, perform the following steps:

    1. Remove the retaining nut and bolt, then push up on the upper control arm until the ball joint stud is clear of the steering knuckle.

    2. Remove the cotter pin and nut from the lower ball joint, then, using the Pitman Arm Puller T64P-3590-F or equivalent, remove the ball joint stud from the knuckle.

    3. Remove the knuckle from the vehicle.

      To install:

  10. Position the steering knuckle on the CV-joint shaft. Check to see if the CV-joint shaft splines are in proper mesh.

  11. Position the spindle's upper arm on the upper ball joint. Install and tighten the nut and bolt to 27-37 ft. lbs. (37-50 Nm). Inspect the upper and lower ball joint boot seals for damage and replace if necessary.

  12. Position the spindle's lower arm over the lower ball joint stud, then slowly lift the lower control arm until the ball joint stud extends through the spindle arm and is seated in the spindle. Install the ball joint castle nut and tighten it to 80-120 ft. lbs. (108-163 Nm) for 1986-90 models, and to 59-81 ft. lbs. (80-110 Nm) for 1991-96 models. Install a new cotter pin through the castle nut. The castle nut may be tightened slightly to align the castellations with the cotter pin hole, but under no circumstances loosen the nut to align them.

  13. Connect the tie rod end to the spindle arm. Firmly seat the tie rod end stud into the tapered hole to prevent rotation while tightening the castellated nut. Torque the tie rod nut to 52-74 ft. lbs. (70-100 Nm), then install a new cotter pin. The castle nut may be tightened slightly to align the castellations with the cotter pin hole, but under no circumstances loosen the nut to align.

  14. Install the rotor and caliper. For more information, refer to Brakes .

  15. Install the front tires, then tighten the lug nuts to 85-115 ft. lbs. (116-155 Nm).

  16. Lower the vehicle.

  17. Tighten the center hub nut to 170-210 ft. lbs. (230-285 Nm).

  18. Install the wheel covers.

If this answer has helped please hit the ACCEPT BUTTON or ask for more help. Positive feedback is always appreciated

Customer: replied 6 years ago.
Reply to Eric's Post: I HAVE THE AWL MODEL AND THE RACK AND PINION ARE INCLOSED IN THE FRAME WITH THE LOWER CONTROL ARM ASST ATTACHED TO THE BOTTOM, I NEED INSTRUCTION ON REMOVING THE LOWER CONTROL ARMS..
Expert:  Eric replied 6 years ago.

Hi,

The above instructions ARE for the AWD version. If you look at the diagram at the beginning of the lower control arm instructions you will see the CV axle in it.I am bringing this up straight from AllData. I have also added the coil spring removal:

REMOVAL & INSTALLATION

See Figures 1, 2, 3 and 4

Click image to see an enlarged view
Fig. 1: Remove the two lower shock retaining screws from the lower control arm

 

Click image to see an enlarged view
Fig. 2: Make sure that the spring compressor is correctly installed in the coil spring, as shown

 

Click image to see an enlarged view
Fig. 3: Matchmark the old spring to help facilitate installation

 

Click image to see an enlarged view
Fig. 4: Use the Pitman arm puller (special tool T64P-3590-F or equivalent) to separate the lower ball joint from the spindle arm

 

  1. Place the steering wheel and front tires in the centered (straight ahead) position. Anytime the steering linkage is disconnected from the spindle, the steering system must be centered prior to beginning any suspension work.

  2. Raise the van and support it safely on jackstands. Place the jackstands beneath the frame at the jacking pads.

  3. Remove the wheel/tire assemblies from the front of the vehicle.

  4. Disconnect the stabilizer bar link bolt from the lower control arm.

  5. Remove the shock absorber, as described later in this section.

  6. Remove the steering center link from the Pitman arm.

  7. Using spring compressor tool D78P-5310-A or equivalent, install one plate with the pivot ball seat facing downward into the coils of the spring. Rotate the plate so that it is flush with the upper surface of the lower arm.

  8. Install the other plate with the pivot ball seat facing upward into the coils of the spring, so that the nut rests in the upper plate.

  9. Insert the compression rod into the opening in the lower arm, through the upper and lower plate and upper ball nut. Insert the securing pin through the upper ball nut and compression rod. This pin can only be inserted one way into the upper ball nut because of a stepped hole design.

  10. With the upper ball nut secured, turn the upper plate so that it walks up the coil until it contacts the upper spring seat, then back it off 1/2 turn.

  11. Install the lower ball nut and thrust washer on the compression rod, then screw on the forcing nut. Tighten the forcing nut until the spring is compressed enough so that it is free in its seat.

  12. Loosen the two lower arm pivot bolts. Remove the cotter pin and loosen, but do not remove the nut attaching the lower ball joint to the spindle. Using Pitman arm puller T64P-3590-F, or equivalent, loosen the lower ball joint.

  13. Remove the puller tool from the lower ball joint.

  14. Support the lower control arm with a hydraulic jack, then remove the ball joint nut. Slowly lower the control arm and remove the coil spring.

  15.  

    1. If the coil spring is being replaced, measure the compressed length of the old spring and mark the position of the compressor plates on the old spring with chalk. Remove the spring compressor from the old spring carefully.

    To install:

    1. Install the spring compressor on the new spring, placing the compressor plates in the same position as marked on the old spring. Make sure the upper ball nut securing pin is installed properly, then compress the new spring to the compressed length of the old spring.

    2. Position the coil spring assembly into the lower control arm.

    3. Place a hydraulic jack under the lower control arm and slowly raise it into position. Reconnect the ball joint and install the nut. Tighten the ball joint castle nut to 80-120 ft. lbs. (108-163 Nm) for 1986-90 models; and to 59-81 ft. lbs. (80-110 Nm) for 1991-96 models, then install a new cotter pin. The nut may be tightened slightly to align the cotter pin hole, but not loosened.

    4. Slowly release the spring compressor and remove it from the coil spring.

    5. Reconnect the steering center link to the Pitman arm.

    6. Install the shock absorber, as described later in this section.

    7. Reconnect the stabilizer bar link bolt to the lower control arm. Tighten the stabilizer link nut to 6-9 ft. lbs. (8-12 Nm).

    8. Install the tire and wheel assemblies.

    9. Lower the vehicle. Although this procedure should not disturb any alignment settings, anytime the front end is disassembled for service, the alignment should be checked.

    10. With the front of the vehicle resting on the ground, tighten the two lower control arm-to-crossmember bolts to 100-140 ft. lbs. (136-190 Nm).

 

Customer: replied 6 years ago.
DO I NEED TO REMOVE THE WHEEL SPINDLE /BRG'S ASSY FROME THE CV JOINT.. I NOT DOING ANY THING WITH THE AXEL...
Expert:  Eric replied 6 years ago.

Hi,

The steering knuckle has to be removed, that is why I included Knuckle/Spindle removal instructions for you. They are right below the lower control removal instructions. The bearing doesnt have to be removed from spindle though.

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