Windstar V6-232 3.8L (1995)
Steering Gear Pinion Bearing Installation
1. Install steering gear pinion bearing in steering gear housing using lower pinion bearing replacer tool No. T78P-3504-G, or equivalent.
2. Apply suitable steering gear grease to pinion oil seal and place it on lower pinion seal replacer tool No. T86P-3504-G, or equivalent, with seal lip
toward tool. Support pinion housing on flat clean surface.
3. Install seal in valve bore, seating it against shoulder.
4. Mount power steering gear input shaft and control end of valve assembly in soft jawed vice. Clamp shaft outside bearing and seal surface.
5. Lubricate mandrel tool No. T75L-3517-A1, or equivalent, with power steering fluid and install over valve assembly. Slide one valve sleeve ring
over tool.
Valve Sleeve Ring Installation
6. Slide pusher tool No. T75L-3517-A2, or equivalent, over mandrel. Rapidly push down on pusher tool, forcing ring down ramp onto valve sleeve.
7. Push ring into bottom groove.
8. Remove valve assembly from vice grip and regrip it with pinion gear teeth.
9. Install mandrel tool No. T75L-3517-A1, or equivalent, over power steering gear input shaft and control. Mandrel will align with third groove.
10. Install third valve sleeve ring by pushing on it rapidly with pusher tool No. T75L-3517-A2, or equivalent. The ring will snap into proper groove.
11. Repeat Step 9 using one spacer for second valve sleeve ring.
12. Repeat Step 9 using two spacers for the first valve sleeve ring.
13. After installing four valve sleeve rings, apply light coat of grease to sleeve and rings.
14. Slowly install sizing tube tool No. T75L-3517-A4, or equivalent, over sleeve valve end of power steering gear input shaft and control onto valve
sleeve rings. Ensure rings are not bent over as tube is slid over them.
15. Remove sizing tube and check condition of rings. Rings should turn freely in grooves.
16. Center steering gear sector shaft in steering gear housing so that equal amounts of steering gear sector shaft stick out of each end of housing.
Position steering gear sector shaft teeth so they will mesh with pinion.
17. Position valve body insertion tool No. T78P-3504-C, or equivalent, in valve housing bore.
