Aerostar 2WD V6-245 4.0L (1990)
5.
For ball joints that use the rivet (N804152-S), install rivet (which replaces the rollpin) using channel locks or equivalent, Figure 8.
6.
Check the inner tie rod function by moving the tie rod spindle. Handshake in various directions.
7.
Apply steering gear grease (C3AZ-19578-A) (ESW-M1CC877-A) to the inner tie rod groove where the boot bellows attach with a clamp to the
inner tie rod. This allows for toe-in adjustments without twisting the bellows.
8.
Apply steering gear grease (C3AZ-19578-A) (ESW-M1CC877-A) to the steering gear housing OD/boot bellows' large OD interface. This layer of
grease will help keep water and contamination from entering the ball joint and rack sealing sur faces.
9.
Install the boot bellows and breather tube.
a.
Check to see that the boot bellows are properly positioned over the steering gear housing bead at the large ID, and are in the tie rod groove
at the small ID.
b.
Check to see that the boot bellows are not twisted and that the vent tube is securely inserted into the vent nipple AT BOTH BOOTS.
c.
At the boot bellows/housing large ID, install screw type (hose) clamps and position screw axis as shown in Figure 9. Tighten screw to
1.7-2.5 lb.ft. (2.3-3.4 N-m).
CAUTION:
DO NOT USE TIE STRAPS TO SECURE BOOT BELLOWS TO STEERING GEAR HOUSING.
d.
At the boot bellows/inner tie rod small ID, install clamp.
10.
Install the jam nut and apply Disc Brake Caliper Slide Grease (D7AZ-19590-A) or equivalent, to the inner tie rod threads.
11.
Install the outer tie rod to the inner tie rod. Count the number of turns recorded earlier. This approximates the previous alignment toe setting.
12.
Tighten the jam nut against the outer tie rod end.
^
For Mustang, Mark, Thunderbird, Cougar, Taurus, Sable, Continental, Aerostar, the torque specification is 35-50 lb.ft. (47-68 N-m).
^
For Tempo/Topaz, the torque specification is 42-50 lb.ft. (57-68 N-m).
13.
Connect the outer tie rod to the steering knuckle.
a.
Tighten the castle nut at the steering knuckle to a minimum 27 lb.ft. (36 N-m).
b.
Continue tightening direction until the hole allows installation of a new cotter pin.
^
For Mustang, Mark, Thunderbird, Cougar, Taurus, Sable, Continental, Aerostar, the torque specification is 35-47 lb.ft. (47-64 N-m).
