Ford Integral Power Steering Gear Box
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'80-96 Bronco PS pitman arm engineering number E2TA-3590-GA
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STEERING GEAR CONDITIONS:
- Feedback (rattle, chuckle, knocking noise in steering gear) Feedback is a condition that is noticed when a truck is driven over rough pavement and this roughness is felt in the steering wheel by the driver. In addition, if the gear is not adjusting properly, excessive rattle, knocking and/or chuckle noises can be heard inside the truck.
Possible Source(s):
* Gear box loose on frame.
Action(s) to Take:
* Check bolts for damage and replace as required. If bolts are not damaged, tighten mounting bolts (3) to 68-84 N-m (50-62 ft-lb).
Possible Source(s):
* Insufficient meshload.
Action(s) to Take:
* Set meshload to specification.
Possible Source(s):
* Loose worm race nut.
Action(s) to Take:
* Check nut for damage and replace as required. If nut is not damaged, tighten nut to 75-122 N-m (50-62 ft-lb)
Possible Source(s):
* Insufficient worm thrust bearing preload.
Action(s) to Take:
* Replace valve assembly.
Possible Source(s):
* Damaged/omitted sector shaft bearing (gear might also exhibit external leakage from sector seals).
Action(s) to Take:
* Replace gear housing.
- Hissing Sound There is some noise in all power steering systems. One of the most common is a hissing sound most evident at standstill parking. There is no relationship between this noise and the performance of the steering gear.
Possible Source(s):
* "Hiss" may be expected when the steering wheel is at the end of travel or when turning it at standstill.
Action(s) to Take:
* Hiss is a normal characteristic of rotary valve steering. Do not replace the input shaft and valve assembly unless the hiss is extremely objectionable. A replacement valve will also exhibit a slight noise and is not usually a cure for the condition. Investigate for a grounded column or a loose boot at the dash panel. Any metal to metal contacts will transmit valve hiss into the passenger compartment through the steering column. Verify clearance between flexible coupling components. Be sure steering column shaft and gear are aligned so flexible coupling rotates in a flat plane and is not distorted as shaft rotates.
- Front End Wander Front end wander is a condition that is noticed when the vehicle is driven in a straight ahead position with the wheel held in a firm position, but the vehicle wanders to either the right or left side. Front end alignment should be checked before any gear service is made.
NOTE: Front end alignment and tire pressures should be checked before any gear service is performed.
Possible Source(s):
* Gear box loose on frame.
Action(s) to Take:
* Check mounting bolts for damage and replace if required. If no damage is found, tighten bolts to 73-90 N-m (54-66 ft-lb).
Possible Source(s):
* Incorrect meshload.
Action(s) to Take:
Set meshload to specification.
Possible Source(s):
* Loose race locknut.
Action(s) to Take:
* Check race locknut for damage and replace as required. If no damage is found, tighten nut to 75-122 N-m (55-90 ft-lb).
Possible Source(s):
* Insufficient worm thrust bearing preload.
Action(s) to Take:
* Replace valve assembly.
Possible Source(s):
* Damaged sector shaft bearing (gear might also exhibit external leakage from sector seals).
Action(s) to Take:
* Replace gear housing assembly.
Possible Source(s):
* Center lash.
Action(s) to Take:
* Improper fit of worm to piston. Replace valve assembly (be certain to check meshload prior to replacing valve for center lash).
- Heavy Steering Efforts, Poor assist (both directions)
Possible Source(s):
* Low steering system fluid fill.
Action(s) to Take:
* Add steering fluid to proper level.
Possible Source(s):
* Engine idle too low.
Action(s) to Take:
* Set engine idle to specification.
Possible Source(s):
* Low power steering pump belt tension.
Action(s) to Take:
* Check belt tension and set to specification.
Possible Source(s):
* Pump flow/relief pressure not to specification.
Action(s) to Take:
* Test pump and service as necessary.
Possible Source(s):
* External leakage resulting in low fluid level.
Action(s) to Take:
* Refer to Ford Power Steering Gear Leak Inspection for external leak diagnosis.
Possible Source(s):
* Piston Teflon® seal cut or twisted.
Action(s) to Take:
* Replace piston Teflon® seal.
Possible Source(s):
* Loose/missing rubber backup piston O-ring.
Action(s) to Take:
* Replace/install rubber backup piston O-ring.
Possible Source(s):
* Valve/gear housing oil passages blocked.
Action(s) to Take:
* Replace gear housing or valve housing as required.
Possible Source(s):
* Leakage past piston end cap.
Action(s) to Take:
* Check piston end cap for damage. If no damage is found, tighten piston end cap to 95-149 N-m (70-110 ft-lb). If damage is found, replace valve assembly.
Possible Source(s):
* Porosity in the piston bore (housing casting).
Action(s) to Take:
* Replace gear housing.
Possible Source(s):
* Porosity in piston.
Action(s) to Take:
* Replace valve assembly.
Possible Source(s):
* Valve sleeve Teflon® seal(s) damaged.
Action(s) to Take:
* Replace valve sleeve Teflon® seal(s).
- External Leakage: One of the most common conditions causing repeat repairs is fluid leaks. Make sure you clean the steering gear first before any steering gear external leakage checks are performed.
Possible Source(s):
* Loose hose fittings.
Action(s) to Take:
* Check hose fittings for damage and replace as required. If no damage is found, tighten fittings to specification.
Possible Source(s):
* Missing/damaged hose fitting tube seats.
Action(s) to Take:
* Install/replace tube seats.
Possible Source(s):
* Leak from input shaft seal.
Action(s) to Take:
* Replace input shaft seal. Check shaft for damage. Check housing bore for porosity or damage.
Possible Source(s):
* Leak at valve mounting face.
Action(s) to Take:
* Check bolts for proper torque. Replace valve housing O-ring(s).
Possible Source(s):
* Leak at sector adjuster screw locknut.
Action(s) to Take:
* Check locknut for damage and replace as required. If no damage is found, tighten locknut to 48-61 N-m (35-45 ft-lb).
Possible Source(s):
* Leak at sector shaft seal.
Action(s) to Take:
* Replace sector seals and examine sector shaft for pitting or corrosion. Replace sector shaft if necessary. Check housing seal bore for porosity or damage. Replace housing if necessary.
Possible Source(s):
* Leak from gear housing.
Action(s) to Take:
* Replace gear housing.
Possible Source(s):
* Leak at sector cover face, or cracked sector cover.
Action(s) to Take:
* Check bolt torques. Check O-ring seal and system relief pressure.
- Poor Returnability -- Sticky Feeling Poor returnability is a condition that is noticed when the vehicle is in a turn and returns to center with effort from the driver. In addition, when the driver returns the steering wheel to center, it may have a sticky or catchy feel.
Possible Source(s):
* Meshload set too tight.
Action(s) to Take:
* Reset meshload to specification.
Possible Source(s):
* Sector adjuster not properly staked to sector.
Action(s) to Take:
* Replace sector assembly.
Possible Source(s):
* Damaged input shaft bearing.
Action(s) to Take:
* Replace valve assembly.
Possible Source(s):
* Binding in valve assembly.
Action(s) to Take:
* Replace valve assembly.
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Steering Box Preload Adjustment (NOT to compensate for wear or slop)
1. Disconnect the pitman arm from the sector shaft using a Pitman Arm Puller (Tool T64P-3590-F).
2. Disconnect the fluid return line at the reservoir and cap the reservoir return line nipple to retain the fluid in the reservoir.
3. Place the end of the return line in a suitable container and turn the steering wheel from stop-to-stop several times to discharge the fluid from the gear. Discard the fluid.
4. Turn the steering wheel to the right stop, then back left 45 degrees.
5. Attach an inch-pound torque wrench to the steering wheel nut and determine the torque required to rotate the shaft slowly approximately one-eighth turn (45°) toward center from the initial 45 degree position. Note this first value.
6. Turn the steering gear back to center and determine the torque required to rotate the shaft back and forth across the center position (± 90°). Compare the center value to the first value, using the following criteria:
* Vehicles with less than 5,000 miles (8046 Km):
If total meshload over mechanical center is less than 15 in-lb (1.7 Nm) or greater than 24 in-lb (2.7 Nm), RESET to first value PLUS 11-15 in-lb (1.2-1.7 Nm).
* Vehicles with more than 5,000 miles (8046 Km), or with new sector shaft:
If meshload over mechanical center is NOT 7 in-lb (0.8 Nm) GREATER than the first value, RESET to 10-14 in-lb (1.13-1.6 Nm) GREATER than first value.
7. If reset is required, loosen the adjuster locknut and turn the sector shaft adjuster screw until the reading is the specified value greater than the torque at 45 degrees from the stop. Hold the sector shaft screw in place, and tighten the locknut.
8. Re-check torque readings and replace the pitman arm and steering wheel hub cover.
9. Connect the fluid return line to the reservoir and fill the reservoir to specification with the specified fluid. Check belt tension & adjust if necessary.
Do not pry against the reservoir to obtain proper belt load. Pressure will deform the reservoir and cause it to leak.
