Bronco L6-300 4.9L VIN Y 1-bbl (1983)
Steering Column: Service and Repair
Assembly
Non-Tilt Column
1.
On vehicles equipped with 3 speed manual transmission, place bushing in socket retainer in outer tube.
2.
On vehicles equipped with 3 speed manual transmission, place bushing on upper hub and wave washer on lower hub of shift socket.
3.
On vehicles equipped with 3 speed manual or automatic transmission, install shift socket in outer tube.
4.
On vehicles equipped with 4 speed manual transmission, install flange extension on outer tube.
5.
Install lock actuator insert in rear of flange and torque screw to 15---25 inch lbs.
6.
Insert lock actuator assembly through opening in front of flange until it bottoms against insert.
7.
Install lock drive gear through lock cylinder opening so that last gear tooth aligns with last tooth on actuator assembly when actuator is fully
rearward.
8.
Install lock bearing, then the lock bearing snap ring.
9.
Place lock cylinder in ``ON'' position and depress retaining pin, then insert lock cylinder into flange.
10.
On vehicles equipped with automatic transmission, attach PRNDL21 insert to front of flange.
11.
On vehicles equipped with manual transmission, position spring on lock release lever assembly and position lever assembly through hole in front
of flange, then tighten spring until lever assembly drops into place.
12.
On vehicles equipped with manual transmission, install snap ring on lock release lever assembly.
13.
On all vehicles, install flange retaining bolts through holes in flange and hand start nuts 1 to 2 threads.
14.
On vehicles equipped with automatic transmission, place wave washer in flange hub.
15.
Install subassembled flange onto outer tube by pinching nuts toward each other and pressing flange in place, then torque nuts to 60---75 inch lbs.
16.
On vehicles equipped with 3 speed manual transmission, assemble shift tube assembly as follows:
a. Install grommets in shift tube, small end facing up.
b. Stack upper spacer, upper arm, lower spacer, and lower arm concentrically in order so that loading slots align.
c. Press entire stack through common loading slot on shift tube, then rotate stack components individually until arms are aligned with their
keyways on shift key and spacers allow shift key to pass freely through operating slots.
17.
On vehicles with 3 speed manual transmission, load shift tube assembly through lower opening of column.
18.
On vehicles equipped with automatic transmission, install shift tube retaining rivet through bottom of shift socket.
19.
On all vehicles, install steering shaft clip below knurl for upper bearing.
20.
On Bronco and F100-350, ensure that shaft assembly length is 35.6 inches, adjusting as necessary by tapping gently in appropriate direction.
21.
Load shaft through bottom of column, being careful not to collapse steering shaft on Bronco and F100-350.
22.
Place cover insulator onto upper bearing and press onto knurl of steering shaft until snap ring groove is visible above bearing.
23.
Install snap ring on steering shaft in groove above bearing.
24.
Install turn signal/hazard warning switch, torquing screws to 15---25 inch lbs.
25.
On E100-350, subassemble lower bearing retainer assembly as follows:
a. Install split retainer sleeve into lower bearing retainer assembly with sleeve shoulder against bearing.
b. Loosely assemble clamp, bolt, and nut to lower bearing retainer assembly, ensuring that bolt aligns with round groove in split retainer sleeve.
c. Push split retainer sleeve shoulder down and push clamp toward bearing, and torque clamp nut to 9-18 ft. lbs.
26.
On Bronco and F100-350, install lower bearing retainer, ensuring that centerline of coupling shaft attachment hole extends .8 inch below lower
face of retainer, and torque screws to 12-20 inch lbs.
27.
On E100-350, install lower bearing retainer and telescope steering column lower bayonet shaft fully toward lower end of column.
28.
Install ignition switch actuator rod.
29.
Install ignition switch and hand start retaining nuts with lock cylinder in lock position.
30.
Torque switch retaining nuts to 40-65 inch lbs. and remove clip.
31.
Install hand shift lever and secure by driving in pivot pin.
32.
Install turn signal switch lever, torquing screws to 30---45 inch lbs.
AEROSTAR, BRONCO II & 1983-87 RANGER
Tilt Column
