Ford Cougar Workshop Service and Repair Manuals | 1998-2001

Alignment Pins, Subframe

205-316 (15-097A)

Separator, Ball Joint

211-020 (13-006)

Expander, Teflon Seal

211-188 (13-015)

1. Disconnect the battery ground cable.

2. Center the steering wheel.
   • Lock in position, remove the ignition key.

3. Disconnect the steering column shaft from the flexible coupling.
   • Rotate the clamp plate to disengage.

4. 

   CAUTION:When removing the floor seal do not damage the sealing clips.
   Remove the floor seal from the bulkhead.
   1. Release the retaining clips.
   2. Disconnect the upper retaining clip.
   3. Remove the floor seal.

5. Remove the steering column shaft flexible coupling.
   • Discard the bolt.

6. Remove the driver side front wheel and tire. For additional information, refer to Section  204-04 Wheels and Tires.

7. Remove the radiator splash shield.

8. Disconnect the fluid cooler line.
   • Allow the fluid to drain into a suitable container.

9. Remove the two fender splash shields.

10. Detach the bumper support brackets from the front subframe.

11. Detach the bumper support brackets from the front subframe.

12. 

    CAUTION:Over bending of the flexible pipe may cause damage resulting in failure.
    Remove the exhaust flexible pipe.
    1. Support the flexible pipe with a support wrap or suitable splint assembly.
    2. Remove and discard the gaskets and nuts.
    3. Detach the exhaust hanger insulator.

13. Detach the engine rear support insulator.

14. Remove the engine rear support insulator center bolt.

15. 

    NOTE:Right-hand drive vehicles with 2.5L engine.
    Remove the engine rear support insulator bracket.

16. 

    CAUTION:Leave the tie-rod end retaining nuts in place to protect the ball joint studs.
    Loosen the tie-rod end retaining nuts.

17. 

    CAUTION:Protect the ball joint seals using a soft cloth to prevent damage.
    Using the special tool, detach the tie-rod ends from the wheel knuckles.
    • Remove and discard the retaining nuts

18. Lower the subframe to gain access to the steering gear tubes.
    1. Loosen the subframe front bolts two complete turns.
    2. Remove the subframe rear bolts.

19. Detach the high-pressure tube support bracket.

20. Detach the high-pressure tube support bracket.

21. 

    NOTE:Left-hand drive shown, right-hand drive similar.
    Detach the return tube support bracket.

22. 

    CAUTION:Whenever the steering gear unions are disconnected the steering gear valve body ports should be plugged to prevent dirt ingress.
    

    NOTE:Left-hand drive shown, right-hand drive similar.
    Disconnect the tube unions from the steering gear.
    1. Disconnect the high-pressure tube union.
    2. Disconnect the return tube union.
    • Allow the fluid to drain into a suitable container.

23. Remove the steering gear cover plate.

24. Remove the steering gear cover plate.

25. 

    CAUTION:Make sure that the pressure check valve does not fall out of the valve body pressure port when the steering gear is being removed.
    

    CAUTION:On right-hand drive vehicles make sure the valve body does not damage the generator wiring harness.
    

    NOTE:Left-hand drive shown, right-hand drive similar.
    Remove the steering gear.

1. Using the special tool, install new union O-ring seals.
   1. Push the new O-ring seal onto the special tool.
   2. Locate the tool over the union and ease the O-ring seal onto the union.

2. 

   CAUTION:Make sure the pressure check valve is correctly located.
   

   NOTE:Left-hand drive shown, right-hand drive similar.
   Install the steering gear.

3. Install the steering gear cover plate.

4. Install the steering gear cover plate.

5. 

   NOTE:Left-hand drive shown, right-hand drive similar
   Connect the tube unions.

6. 

   NOTE:Left-hand drive shown, right-hand drive similar.
   Install the return tube support bracket.

7. Install the high-pressure tube support bracket.

8. Install the high-pressure tube support bracket.

9. Using the special tool, align the subframe.
   1. Install the alignment pins in the subframe aligning holes.
   2. Install the locking pins.
   3. Tighten the alignment pin sleeves.

10. Install and secure the subframe bolts.

11. Remove the special tool (subframe alignment pins).

12. Install the engine rear support insulator.

13. 

    NOTE:Right-hand drive vehicles with 2.5L engine.
    Install the engine rear support insulator bracket.

14. Install the engine rear support insulator center bolt.

15. 

    CAUTION:Over bending of the flexible pipe may cause damage resulting in failure.
    

    NOTE:Install new gaskets and nuts.
    Install the exhaust flexible pipe.
    • After installation, remove the flexible pipe support.

16. 

    WARNING:Install new tie-rod end retaining nuts. Failure to follow this instruction, may result in personal injury.
    Attach the tie-rod ends to the wheel knuckles.

17. Install the two fender splash shields.