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Power Steering

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Power Steering

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2000 Ford Pickup F350 Super Duty

2000-01 STEERING Power Steering Systems - Excursion, Super-Duty & Motorhome Chassis

2000-01 STEERING

Power Steering Systems - Excursion, Super-Duty & Motorhome Chassis

DESCRIPTION & OPERATION

STEERING GEAR

The steering gear has the following features:

z It is a torsion-bar type hydraulic assisted system.

z It reduces road shock and vibration.
z It includes a rotary-style hydraulic valve.
z It uses a dot matrix ID mark on the gear housing between the valve housing and the sector shaft housing
cover.

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Thursday, November 09, 2006 7:09:14 PM Page 10 © 2004 Mitchell Repair Information Company, LLC.
2000 Ford Pickup F350 Super Duty
2000-01 STEERING Power Steering Systems - Excursion, Super-Duty & Motorhome Chassis

Fig. 10: Identifying Power Steering Components (7.3L Engine)

Courtesy of FORD MOTOR CO.

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Thursday, November 09, 2006 7:09:14 PM Page 11 © 2004 Mitchell Repair Information Company, LLC.
2000 Ford Pickup F350 Super Duty
2000-01 STEERING Power Steering Systems - Excursion, Super-Duty & Motorhome Chassis

5. Verify that there is no air in the power steering system. Run the engine until it reaches normal operating
temperature. Turn the steering wheel to the left and right several times without hitting the stops. If any air
bubbles are present, purge power steering system. See BLEEDING under LUBRICATION.
6. With the ignition switch at OFF, wipe off the power steering pump, power steering pressure hose, power
steering return hose, power steering fluid cooler and steering gear. With the engine running, turn the
steering wheel from stop to stop several times. Do not hold steering wheel at stops. Check for leaks.
Repair as necessary if leaks are observed.
7. Visually inspect for obvious signs of mechanical damage.
z Loose tie rod ends

z Loose suspension components

z Loose steering column shaft universal joints

z Loose steering gear mounting bolts

z Binding or misaligned steering column

z Power steering pump

z Bent or pinched power steering lines

8. If an obvious cause for an observed or reported malfunction is found, correct the cause (if possible)
before proceeding to the next step.
9. If the fault is not visually evident, diagnose by symptom. See SYMPTOMS .

STEERING SYSTEM SYMPTOM DEFINITIONS

Drift/Pull

Pull is a tugging sensation, felt by the hands on the steering wheel, that must be overcome to keep the vehicle
going straight. Drift describes what a vehicle with this condition does with hands off the steering wheel.

z A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead path
and require constant steering input in the opposite direction to counteract the effect.
z Drift/pull may be induced by conditions external to the vehicle (i.e., wind, road camber).

Excessive Steering Wheel Play

Excessive steering wheel play is a condition in which there is too much steering wheel movement before the
wheels move. A small amount of steering wheel free play is considered normal.

Feedback

Feedback is a roughness felt in the steering wheel when the vehicle is driven over rough pavement.

Hard Steering Or Lack Of Assist

Hard steering can remain constant through the full turn or occur near the end of a turn. It is important to know
the difference between hard steering/lack of assist and binding. Hard steering or lack of assist can result from
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2000 Ford Pickup F350 Super Duty
2000-01 STEERING Power Steering Systems - Excursion, Super-Duty & Motorhome Chassis

either hydraulic or mechanical conditions. It is extremely important to know if this concern occurs during
driving, during very heavy or static parking maneuvers.

Nibble

Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various road
surfaces and observed by the driver as small rotational oscillations of the steering wheel.

Poor Returnablility/Sticky Steering

Poor returnability and sticky steering is used to describe the poor return of the steering wheel to center after a
turn or the steering correction is completed.

Shimmy

Shimmy, as observed by the driver, is large, consistent, rotational oscillations of the steering wheel resulting
from large, side-to-side (lateral) tire/wheel movements. Shimmy is usually experienced near 64 km/h (40 mph),
and can begin or be amplified when the tire contacts pot holes or irregularities in the road surface.

Wander

Wander is the tendency of the vehicle to require frequent, random left and right steering wheel corrections to
maintain a straight path down a level road.

SYMPTOMS

Hard Steering Or Lack Of Assist

If a hard steering or lack of assist condition is found, possible sources include the following:

z Seized lower steering column shaft U-joints. See STEERING COLUMNS -- EXCURSION, E350,
F250/350/450/550 SUPER DUTY & STRIPPED CHASSIS .
z Damaged or fractured steering column bearing(s). See STEERING COLUMNS -- EXCURSION,
E350, F250/350/450/550 SUPER DUTY & STRIPPED CHASSIS .
z Power steering pump. See PUMP FLOW & PRESSURE TEST under DIAGNOSIS & TESTING.
z Suspension components.
z Steering gear internal leakage. See PUMP FLOW & PRESSURE TEST under DIAGNOSIS &
TESTING.

Excessive Pump Noise

If an excessive pump noise condition is found, test power steering pump. See PUMP FLOW & PRESSURE
TEST under DIAGNOSIS & TESTING.

Excessive Steering Wheel Play

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2000 Ford Pickup F350 Super Duty
2000-01 STEERING Power Steering Systems - Excursion, Super-Duty & Motorhome Chassis

If an excessive steering wheel play condition is found, possible sources include the following:

z Loose, worn or damaged steering linkages or tie rod end. See STEERING LINKAGE TEST under
DIAGNOSIS & TESTING.
z Loose steering gear bolts. Tighten steering gear bolts to specification. See TORQUE
SPECIFICATIONS .
z Damaged or worn steering gear. See STEERING GEAR under OVERHAUL.
z Loose, worn or damaged steering column bearing(s). See STEERING COLUMNS -- EXCURSION,
E350, F250/350/450/550 SUPER DUTY & STRIPPED CHASSIS .
z Loose, worn or damaged lower steering column shaft U-joints. See STEERING COLUMNS --
EXCURSION, E350, F250/350/450/550 SUPER DUTY & STRIPPED CHASSIS .

Steering Wanders

If a wandering condition is found, possible sources include the following:

z Unevenly loaded or overloaded vehicle. If this condition is found, notify vehicle owner of improper
vehicle loading.
z Loose or damaged steering gear mounting bolts. If this condition is found, tighten steering gear bolts to
specification. See TORQUE SPECIFICATIONS .
z Loose lower steering column U-joint bolts. See STEERING COLUMNS -- EXCURSION, E350,
F250/350/450/550 SUPER DUTY & STRIPPED CHASSIS .
z Loose, worn or damaged lower steering column shaft U-joints. See STEERING COLUMNS --
EXCURSION, E350, F250/350/450/550 SUPER DUTY & STRIPPED CHASSIS .
z Wheel alignment. See SPECIFICATIONS & PROCEDURES -- TRUCKS .
z Loose, worn or binding steering linkage(s) or tie rod end(s). See STEERING LINKAGE TEST under
DIAGNOSIS & TESTING.
z Improper steering gear preload/meshload. See MESHLOAD ADJUSTMENT under ADJUSTMENTS
& INSPECTION.
z Suspension components. See FRONT -- 4WD LEAF SPRING or FRONT -- 2WD EXCURSION,
F250 & F350 SUPER DUTY under SUSPENSION.

Drift Or Pull

If a Drift/Pull condition is found, possible sources include the following:

z Unevenly loaded or overloaded vehicle. If this condition is found, notify vehicle owner of improper
vehicle loading.
z Wheel alignment. See SPECIFICATIONS & PROCEDURES -- TRUCKS .
z Loose, worn or binding steering linkage(s) or tie rod end(s). See STEERING LINKAGE TEST under
DIAGNOSIS & TESTING.
z Suspension components. FRONT -- 4WD LEAF SPRING or FRONT -- 2WD EXCURSION, F250 &
F350 SUPER DUTY article under SUSPENSION.

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2000 Ford Pickup F350 Super Duty
2000-01 STEERING Power Steering Systems - Excursion, Super-Duty & Motorhome Chassis

z The steering gear valve effort out of balance. See STEERING GEAR VALVE TEST under
DIAGNOSIS & TESTING.
z Check the brake system for proper operation.
z Improper frame/underbody alignment. If this condition is found, correct as necessary.

Feedback

If a Feedback condition is found, possible sources include the following:

z Loose, worn or damaged steering linkage(s) or tie rod end(s). See STEERING LINKAGE TEST under
DIAGNOSIS & TESTING.
z Loose or damaged steering gear mounting bolts. If this condition is found, tighten steering gear bolts to
specification. See TORQUE SPECIFICATIONS .
z Loose lower steering column shaft U-joint bolts. See STEERING COLUMNS -- EXCURSION, E350,
F250/350/450/550 SUPER DUTY & STRIPPED CHASSIS article in CHASSIS SERVICE &
REPAIR.
z Loose suspension bushings, fasteners or ball joints. See FRONT -- 4WD LEAF SPRING or FRONT --
2WD EXCURSION, F250 & F350 SUPER DUTY article under SUSPENSION.
z Worn or damaged steering column bearing(s). See STEERING COLUMNS -- EXCURSION, E350,
F250/350/450/550 SUPER DUTY & STRIPPED CHASSIS article in CHASSIS SERVICE &
REPAIR.

Sticky Steering, Poor Returnability

If a Sticky Steering/Poor Returnability condition is found, possible sources include the following:

z Binding lower steering column shaft U-joints. See STEERING COLUMNS -- EXCURSION, E350,
F250/350/450/550 SUPER DUTY & STRIPPED CHASSIS .
z Loose, worn or binding steering linkage(s) or tie rod end(s). See STEERING LINKAGE TEST under
DIAGNOSIS & TESTING.
z Check the steering gear for evidence of binding or damage. See STEERING GEAR under OVERHAUL.
z Suspension components. See FRONT -- 4WD LEAF SPRING or FRONT -- 2WD EXCURSION,
F250 & F350 SUPER DUTY article under SUSPENSION.
z Wheel alignment. See SPECIFICATIONS & PROCEDURES -- TRUCKS .
z Binding steering column bearing(s). See STEERING COLUMNS -- EXCURSION, E350,
F250/350/450/550 SUPER DUTY & STRIPPED CHASSIS .
z Power steering pump. See PUMP FLOW & PRESSURE TEST under DIAGNOSIS & TESTING.

Shimmy

If a Shimmy condition is found, possible sources include the following:

z Loose, worn or damaged steering linkage(s) or tie rod end(s). See STEERING LINKAGE TEST under
DIAGNOSIS & TESTING.
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2000 Ford Pickup F350 Super Duty
2000-01 STEERING Power Steering Systems - Excursion, Super-Duty & Motorhome Chassis

z Suspension system components. See FRONT -- 4WD LEAF SPRING or FRONT -- 2WD
EXCURSION, F250 & F350 SUPER DUTY article under SUSPENSION.

DIAGNOSIS & TESTING

STEERING LINKAGE TEST

NOTE: Excessive vertical motion of the studs relative to the sockets may indicate
excessive wear.

1. With the parking brake applied, perform the following:

z Have an assistant rotate the steering wheel back and forth 360 degrees and watch for relative
motion of the studs in the steering linkage ball sockets.
z Watch for loose steering gear mounting.

2. Another method is to raise the front wheels off the ground, grasp the wheel at the front and rear and
watch for excessive play or binding in the joints while trying to steer the wheels.
3. Replace or tighten any worn, damaged, or loose tie rods, tie rod ends, linkages or components. See
appropriate procedure under REMOVAL & INSTALLATION .

PUMP FLOW & PRESSURE TEST

WARNING: Do not touch the flowmeter during the test procedure, or severe burns
and serious injury may occur.

CAUTION: Make sure that the connection point will not interfere with any of the
engine accessory drive components or drive belts.

1. Install the Power Steering Analyzer (211-F001) or equivalent at the high pressure port of the power
steering pump. Make sure the power steering analyzer gate valve is fully open. On some vehicles, the
power steering pump high pressure port is inaccessible and the power steering analyzer should then be
installed either at the steering gear or at a point in the high pressure line between the power steering pump
and the steering gear.
2. Place a Dial Thermometer (023-R0007) in the power steering oil reservoir.
3. Check the power steering fluid level. If necessary, add power steering fluid. Use Motorcraft MERCON
(R) Multi-Purpose ATF XT-2-QDX or MERCON(R) equivalent.
4. Install a digital tachometer.
5.
CAUTION: Do not hold the steering wheel against the stops for more than three
to five seconds at a time. Damage to the power steering pump will
occur.

Start the engine. Place the transmission in neutral. Set the parking brake. Raise the power steering fluid
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2000 Ford Pickup F350 Super Duty
2000-01 STEERING Power Steering Systems - Excursion, Super-Duty & Motorhome Chassis

temperature to 165-175°F (74-80°C) by rotating the steering wheel fully to the left and right several
times.
6. Set the engine speed to 1500 RPM. Record the flow rate and pressure readings. If the flow rate is below
the flow rate specification, the power steering pump may require replacement. See POWER STEERING
PUMP under REMOVAL & INSTALLATION. Continue with the test procedure. If the pressure reading
is above the maximum pressure specification, then check power steering hoses for kinks and restrictions.
See GENERAL SPECIFICATIONS .
7. Partially close the gate valve to obtain 750 psi. Set the engine speed at idle. Record the flow rate. If the
flow is less than the specified flow rate, then replace the power steering pump. See GENERAL
SPECIFICATIONS .
8.
CAUTION: Do not allow the gate valve to remain closed for more than 5
seconds.

Completely close and partially open the gate valve 3 times. Record the pressure relief valve actuation
pressure reading. If the pressure does not meet the relief pressure specification, then replace the power
steering pump.
9. Set engine speed to 1500 RPM. Record the flow rate. If the flow rate varies more than 3.785 liters/minute
(1 gallon/minute) from the initial flow rate reading, then replace the power steering pump.
10.
CAUTION: Do not hold the steering wheel against the stops for more than three
to five seconds at a time. Damage to the power steering pump will
occur.

Set the engine speed at idle. Turn (or have an assistant turn) the steering wheel to the left and right stops.
Record flow rate and pressure readings at the stops. The pressure reading at both stops should be nearly
the same as the maximum pump relief pressure. The flow rate should drop below 1.9 liters/minute (0.5
gallons/minute). If the pressure does not reach the maximum pump relief pressure or the flow rate does
not drop below the specified value, excessive internal leakage is occurring. Repair or replace the steering
gear. See STEERING GEAR under REMOVAL & INSTALLATION.
11. Turn (or have an assistant turn) the steering wheel slightly in both directions and release quickly while
watching the pressure gauge. The pressure reading should move from the normal back pressure reading
and snap back as the steering wheel is released. If the pressure returns slowly or sticks, the rotary valve in
the steering gear is sticking or the steering column is binding. Check the steering column and linkages
before servicing the steering gear.

STEERING GEAR VALVE TEST

1. With the vehicle in motion, place the transmission in NEUTRAL and turn the engine OFF. If the vehicle
does not pull with the engine OFF, repair or replace the steering gear. See STEERING GEAR under
REMOVAL & INSTALLATION.
2. If the vehicle pulls with the engine OFF, cross-switch the front wheels. If the vehicle pulls to the opposite
side, cross-switch the front and rear wheels on the same side.
3. If the vehicle pull direction does not change, check the front suspension components, wheel alignment
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2000 Ford Pickup F350 Super Duty
2000-01 STEERING Power Steering Systems - Excursion, Super-Duty & Motorhome Chassis

and frame alignment.

LUBRICATION
FLUID TYPE

Manufacturer suggests using MERCON(R) Multi-Purpose ATF XT-2-QDX fluid.

SYSTEM FLUSHING

WARNING: Do not mix oil types. Any mixture or any unapproved oil can lead to seal
deterioration and leaks. A leak can ultimately cause loss of fluid, which
can result in a loss of power steering assist.

CII Power Steering Pump

1. Remove the injector driver module (IDM) relay to prevent engine starting. See Fig. 16 .IDM relay is in
battery junction box, in left rear corner of engine compartment next to master cylinder.
2. Loosen the two clamps. Remove the air intake tube. See Fig. 17 .

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2000 Ford Pickup F350 Super Duty
2000-01 STEERING Power Steering Systems - Excursion, Super-Duty & Motorhome Chassis

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Thursday, November 09, 2006 7:09:14 PM Page 24 © 2004 Mitchell Repair Information Company, LLC.
2000 Ford Pickup F350 Super Duty
2000-01 STEERING Power Steering Systems - Excursion, Super-Duty & Motorhome Chassis

Fig. 16: Removing IDM Relay

Courtesy of FORD MOTOR CO.

Fig. 17: Removing Air Intake Tube

Courtesy of FORD MOTOR CO.

3. Disconnect the power steering return hose. Plug the reservoir fitting.
4. Attach an extension hose between the power steering return hose and an empty container.
5. Raise the front wheels off the floor.
6. Fill the reservoir. Use Motorcraft MERCON(R) Multi-Purpose ATF XT-2-QDX or equivalent MERCON
(R) fluid.
7.
CAUTION: Do not crank the engine for more than 15 seconds at a time. Allow
the starter to cool for 1 minute before cranking again. Premature
starter failure can occur.

CAUTION: Do not hold the steering wheel against the stops for more than three
to five seconds at a time. Damage to the power steering pump could
occur.

Check the power steering fluid level. Use Motorcraft MERCON(R) Multi-Purpose ATF XT-2-QDX or
equivalent MERCON(R) fluid.

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2000 Ford Pickup F350 Super Duty
2000-01 STEERING Power Steering Systems - Excursion, Super-Duty & Motorhome Chassis

Fig. 21: Filling Power Steering Reservoir

Courtesy of FORD MOTOR CO.

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Thursday, November 09, 2006 7:09:15 PM Page 32 © 2004 Mitchell Repair Information Company, LLC.
2000 Ford Pickup F350 Super Duty
2000-01 STEERING Power Steering Systems - Excursion, Super-Duty & Motorhome Chassis

ZF Power Steering Pump

NOTE: This procedure is for motorhome vehicles equipped with either the Hydro-Boost
or Hydro-Max brake systems.

1. Remove the fuel pump fuse to prevent engine starting. See Fig. 19 . Fuel pump fuse is in battery junction
box, in left rear corner of engine compartment next to master cylinder.
2. Disconnect the power steering return hose. Plug the reservoir fitting (power steering fluid cooler to power
steering oil reservoir).
3. Attach an extension hose between the power steering return hose and an empty container.
4. Raise the front wheels off the floor.
5. Fill the reservoir. Use Motorcraft MERCON(R) Multi-Purpose ATF XT-2-QDX or equivalent MERCON
(R) fluid.
6.
CAUTION: Do not crank the engine for more than 15 seconds at a time. Allow
the starter to cool for 1 minute before cranking again. Premature
starter failure can occur.

CAUTION: Do not hold the steering wheel against the stops for more than three
to five seconds at a time. Damage to the power steering pump could
occur.

Turn the steering wheel from stop-to-stop while cranking the engine until the fluid exiting the power
steering return hose is clear of all contamination and debris. Add fluid as needed. Use Motorcraft
MERCON(R) Multi-Purpose ATF XT-2-QDX or equivalent MERCON(R) fluid.
7. Lower the vehicle.
8. Disconnect the extension hose from the power steering return hose. See Fig. 22 . Remove the plug.
Attach the power steering return hose to the reservoir.

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2000 Ford Pickup F350 Super Duty
2000-01 STEERING Power Steering Systems - Excursion, Super-Duty & Motorhome Chassis

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Thursday, November 09, 2006 7:09:15 PM Page 34 © 2004 Mitchell Repair Information Company, LLC.
2000 Ford Pickup F350 Super Duty
2000-01 STEERING Power Steering Systems - Excursion, Super-Duty & Motorhome Chassis

Fig. 22: Disconnecting Extension Hose

Courtesy of FORD MOTOR CO.

9. Fill the reservoir. Use Motorcraft MERCON(R) Multi-Purpose ATF XT-2-QDX or equivalent MERCON
(R) fluid.
10. Install the fuel pump fuse.
11.
CAUTION: Do not hold the steering wheel against the stops for more than three
to five seconds at a time. Damage to the power steering pump could
occur.

Start the engine and turn the steering wheel from stop-to-stop.
12.
NOTE: If the power steering system is noisy and accompanied by evidence of
aerated fluid it will be necessary to purge the power steering system.

Check the power steering fluid level. See Fig. 23 .

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2000 Ford Pickup F350 Super Duty
2000-01 STEERING Power Steering Systems - Excursion, Super-Duty & Motorhome Chassis

Fig. 23: Checking Fluid Level

Courtesy of FORD MOTOR CO.
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2000 Ford Pickup F350 Super Duty
2000-01 STEERING Power Steering Systems - Excursion, Super-Duty & Motorhome Chassis

BLEEDING

CAUTION: If the air is not purged from the power steering system correctly,
premature power steering pump failure could result. This condition can
occur on pre-delivery vehicles with evidence of aerated fluid or on
vehicles that have had steering component repairs.

NOTE: A whine heard from the power steering pump may be caused by air in the
system. The power steering purge procedure must be performed prior to any
component repair for which power steering noise complaints are accompanied
by evidence of aerated fluid.

CII Pump

1. Remove the reservoir cap. Check the fluid.

2. Tightly insert the stopper of the Vacuum Pump (D95L-7559-A) or equivalent into the reservoir.
3. Start the vehicle.
4. Apply maximum vacuum and maintain it for a minimum of three minutes with the engine speed set at
idle.
5. Release the vacuum and remove the vacuum pump.
6.
CAUTION: Do not overfill the reservoir.

Fill the reservoir.

7. Reinstall the vacuum pump. Apply and maintain maximum vacuum. Fig. 24
8.
CAUTION: Do not hold the steering wheel against the stops for more than three
to five seconds at a time. Damage to the power steering pump could
occur.

Cycle the steering wheel fully to the left and right every 30 seconds for approximately five minutes.
9. Stop the engine, release the vacuum, and remove the vacuum pump.
10. Install the reservoir cap.
11. Check for fluid leaks at all of the connections. If the power steering fluid shows signs of air, repeat this
procedure.

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2000 Ford Pickup F350 Super Duty
2000-01 STEERING Power Steering Systems - Excursion, Super-Duty & Motorhome Chassis

Fig. 24: Applying Vacuum To CII Pump

Courtesy of FORD MOTOR CO.

CIII Pump

1. Remove the reservoir cap. See Fig. 21 . Check the fluid. Use Motorcraft MERCON(R) Multi-Purpose
ATF XT-2-QDX or MERCON(R) equivalent.
2. Tightly insert the stopper of the vacuum pump into the reservoir.
3. Start the vehicle.
4. Apply maximum vacuum and maintain it for a minimum of three minutes with the engine speed set at
idle. See Fig. 25 .

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2000 Ford Pickup F350 Super Duty
2000-01 STEERING Power Steering Systems - Excursion, Super-Duty & Motorhome Chassis

Fig. 25: Applying Vacuum To CIII Pump

Courtesy of FORD MOTOR CO.

5. Release the vacuum and remove the vacuum pump.

6.
CAUTION: Do not overfill the reservoir.

STEERING GEAR COMPONENT INSPECTION (MOTORHOME)

NOTE: Make sure that all seal surfaces and seal cavities are free from nicks and
corrosion. If any part is nicked or corroded where sealing occurs, install new
parts to make sure they seal correctly. Wash all parts in a clean petroleum-base
solvent. Blow air on the parts until dry.

1. Inspect the housing cylinder bore. Some scoring marks are normal. If there is internal leakage greater than
3.8 liters/min. (1.0 gpm), make sure there are no damaged seals before installing the housing. See Fig.

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Thursday, November 09, 2006 7:09:15 PM Page 44 © 2004 Mitchell Repair Information Company, LLC.
2000 Ford Pickup F350 Super Duty
2000-01 STEERING Power Steering Systems - Excursion, Super-Duty & Motorhome Chassis

29 .

Fig. 29: Inspecting The Housing Cylinder Bore

Courtesy of FORD MOTOR CO.

2. Inspect the housing faces for nicks that would prevent correct sealing. Install a new gear housing if these
nicks are present and cannot be easily removed with a fine-tooth flat file without changing the
dimensional characteristics, or if depressions are located in a seal area. See Fig. 30 .

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2000 Ford Pickup F350 Super Duty
2000-01 STEERING Power Steering Systems - Excursion, Super-Duty & Motorhome Chassis

Fig. 30: Inspecting Housing Faces

Courtesy of FORD MOTOR CO.

Thursday, November 09, 2006 7:09:15 PM Page 49 © 2004 Mitchell Repair Information Company, LLC.
2000 Ford Pickup F350 Super Duty
2000-01 STEERING Power Steering Systems - Excursion, Super-Duty & Motorhome Chassis

Fig. 34: Inspecting Side Cover DU Bushing

Courtesy of FORD MOTOR CO.

9.
NOTE: A service sector shaft assembly will have the adjusting screw and the
retainer installed. The screw and the retainer can be repaired separately.

Inspect the bearing, sealing and tooth contact surfaces on the sector shaft. Remove all masking tape from
the sector shaft. Check for brinelling, spalling or cracks. Run the edge of a fingernail across these areas to
detect steps and inspect for cracks. Look for twisted or damaged serrations. Install a new sector shaft if
any of these conditions exist. See Fig. 35 .
10. If damaged, remove and install a new poppet fixed stop screw and washer. Tighten to specification. See
TORQUE SPECIFICATIONS .
11. If damaged, remove the poppet adjusting screw and sealing nut without allowing the nut to change its
position on the screw. See Fig. 36 .

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2000 Ford Pickup F350 Super Duty
2000-01 STEERING Power Steering Systems - Excursion, Super-Duty & Motorhome Chassis

Fig. 35: Inspecting Sector Shaft

Courtesy of FORD MOTOR CO.

Fig. 36: Removing Sealing Nut

Courtesy of FORD MOTOR CO.

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2000 Ford Pickup F350 Super Duty
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12. Assemble the new nut onto the new adjusting screw, matching its position to the nut and screw removed.
Tighten the sealing nut to specification. See Fig. 37 .

Fig. 37: Installing New Stop Screw

Courtesy of FORD MOTOR CO.

13.
NOTE: If damaged, remove and install a new permanent auxiliary port plugs and
O-rings.

Assemble new O-rings on the port plugs and tighten to their respective ports in the housing or valve
housing to specification. See Fig. 38 .

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2000 Ford Pickup F350 Super Duty
2000-01 STEERING Power Steering Systems - Excursion, Super-Duty & Motorhome Chassis

Fig. 38: Installing Port Plugs

Courtesy of FORD MOTOR CO.

14. If damaged, remove the grease fitting from the housing. If the fitting is broken off, use the suitable
extractor to remove it.
15. To install, hold a piece of tubing that will clear the head of the fitting over a new fitting and tap the fitting
into the housing. See Fig. 39 .

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2000 Ford Pickup F350 Super Duty
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Fig. 39: Installing New Grease Fitting

Courtesy of FORD MOTOR CO.

16. Inspect the steering gear housing for cracks and stripped threads and the mating surfaces for burrs.
17. Inspect the piston bore for scoring or wear.
18. Install a new steering gear housing, if necessary. Surface burnishing is acceptable if no significant step
can be felt.

STEERING GEAR ADJUSTMENT (MOTORHOME)

NOTE: This resetting procedure will work in most cases with at least 1-3/4 hand wheel
turns from side to side of center. If making a large reduction in wheel cut and
this procedure does not work, the poppets may need to be internally reset.

The steering gear is equipped with two hydraulic pressure-relieving poppet valves that were automatically set to
trip, relieving pressure just before reaching the axle stops. This was achieved after initial installation into the
vehicle at the first full right and left turns. The pressure-relieving poppet valves will automatically reset
themselves within the poppet adjustment limits if the axle stops are reset for increased steering gear travel based
on acceptable equipment revisions from original factory installations.

Poppet Valve Manual Readjustment

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1. To determine if the poppets require readjustment or if they are carried out correctly, install a Power
Steering System Analyzer (PSSA) between the power steering pump and the steering gear. If poppet
readjustment is necessary, you can leave the PSSA in the system to verify that the following procedure is
completed correctly.
2. Poppets might need to be readjusted if the following conditions exist:
z Changing to larger tires

z Reduced vehicle wheelcut

z Pitman arm mistimed, condition corrected

z Steering gear being installed on a different truck

z Steer axle stop bolt(s) were bent or broken

z Steer axle U-bolt(s) were bent or broken

3.
NOTE: An alternate method of manually resetting the poppet valves with the
steering gear installed in the vehicle is done by using Ross special service
tools, Poppet Adjuster Tool (J37070) and Adjuster Lock Nut Tool (J37464).

Check the maximum turn angle of the front wheels.

4.
NOTE: The steering gear will have either a fixed stop screw or an adjusting screw.
If the adjusting screw is already part of the steering gear, back the nut off
the adjusting screw until it is flush with the end of the adjusting screw.

NOTE:

Only perform this step with the wheels in the straight-ahead position, the steering gear in its center
position and only when the timing marks on the end of the sector shaft and the housing trunnion are
aligned. Turn adjusting tool into the non-sealing end of adjuster lock nut tool until the drive end of the
screw is flush with the nut. See Fig. 40 .

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Fig. 40: Aligning Adjusting Screw Flush With Nut

Courtesy of FORD MOTOR CO.

5.
NOTE: If the unit has a poppet adjusting screw and sealing nut that need to be
replaced, remove and discard them.

With the vehicle unloaded, the engine off and the wheels in the straight-ahead position, remove and
discard the fixed stop screw, if so equipped, and the washer from the lower end of the housing.

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Fig. 41: Removing Fixed Stop Screw

Courtesy of FORD MOTOR CO.

6. Install the adjusting screw and the sealing nut assembly (without moving the nut on the screw) into the
housing until the nut is firmly against the housing. Tighten the sealing nut against the housing.

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Fig. 42: Installing Adjusting Screw & Sealing Nut

Courtesy of FORD MOTOR CO.

7.
CAUTION: Do not mix fluid types. Mixing transmission fluid, motor oil, or other
hydraulic fluids will cause seals to deteriorate faster.

Fill the power steering reservoir with the specified fluid.

8. Place a jack under the center of the front axle and jack up the front end of the vehicle so the steering axle
tires are off the ground.
9. Start the engine and let it run at idle speed.
10. Note which output shaft timing mark is nearest the housing piston bore.
11. Turn the steering wheel to make right-hand turn (which makes the pitman arm turn in a counterclockwise
direction toward the poppet adjusting screw). Turn in this direction until axle stop contact is made.
12. Pull hard on the steering wheel (put 30 pounds of rim pull on a 20-inch diameter steering wheel) after the
axle stop is contacted.
13. Turn the steering wheel in the opposite direction (end of timing mark away from the adjusting screw)
until the other axle stop is contacted.
14. Pull hard on the steering wheel (put 44 pounds of rim pull on an 18-inch diameter steering wheel).
15. Release the steering wheel and shut off the engine. Do not steer again until step 18 is completed.
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16. Loosen the sealing nut and back out the adjusting screw until it is past the nut. Tighten the sealing nut
against the housing. See Fig. 43 .

Fig. 43: Tightening Sealing Nut

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NOTE: The front wheel should not touch the ground.

Lower and support the front of the vehicle.

7.
NOTE: Reset the steering gear meshload only if the measured rotating torque for
total on-center load if less than specification. See GENERAL
SPECIFICATIONS .

Attach an INCH pound torque wrench to the bolt and measure the steering gear meshload from center.
See Fig. 46 .
8. Adjust steering gear meshload if rotating torque is not within specification. See Fig. 47 .

Fig. 46: Measuring Steering Gear Meshload (XR 50 Steering Gear)

Courtesy of FORD MOTOR CO.

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Fig. 47: Adjusting Sector Shaft (XR 50 Steering Gear)

Courtesy of FORD MOTOR CO.

9. Remove the fan blade assembly and fan shroud.

10. Adjust the sector shaft to proper rotating torque. Hold the sector shaft and loosen the lock nut. Adjust the
sector shaft.
11. Verify that the rotating torque is to specification. Reset if necessary.
12. Tighten the lock nut. Hold the sector shaft. Tighten the lock nut.
13. Install the steering sector shaft arm drag link, castellated nut and cotter pin.
14. Lower the vehicle.
15. Install the driver air bag.

TAS40 Steering Gear

CAUTION: This adjustment must be performed with the sector shaft on its center of
travel. The input shaft must not be rotated more than 1-1/2 revolutions
when the steering sector shaft arm drag link is disconnected from the
steering gear to avoid possible misadjustment of the automatic poppet
system.

NOTE: If the adjusting screw jam nut screw is accessible, this adjustment can be
completed on the vehicle. Otherwise, the steering gear must be removed from
the vehicle. If this adjustment is being performed with the steering gear on the
vehicle, disconnect the steering sector shaft arm drag link.

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1. Put the sector shaft in the center of travel. Rotate the input shaft until the timing marks across the end of
the sector shaft are perpendicular to the input shaft and the valve worm is in line with the timing mark on
the end of the housing trunnion. See Fig. 48 .

Fig. 48: Centering Sector Shaft (TAS40 Steering Gear)

Courtesy of FORD MOTOR CO.

2. With the steering gear in the center position, grasp and gently try to move the steering sector shaft arm
drag link back and forth in the direction of travel. Fingertip force is adequate to detect the lash of a loose
sector shaft. There must be no movement of the input shaft or the sector shaft.
3. Loosen the jam nut on the sector shaft adjusting screw. If no lash was detected, turn the adjusting screw
counterclockwise until lash is detected at the output shaft.
4.
CAUTION: Overadjustment of the shaft adjusting screw in the clockwise
direction can result in a no-recovery, oversteering or darting
condition of the vehicle.

Adjust the shaft adjusting screw. Slowly turn the adjusting screw clockwise until no lash is felt at the
steering sector shaft arm drag link. Use no more than the specified torque. From the no-lash position, turn
the screw clockwise an additional 1/8-3/16 turn. Hold the adjusting screw in place and tighten the jam nut
to specification.

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5. Turn the input shaft 1/4-turn each side of center and recheck the steering sector shaft arm drag link for
lash. No lash should be felt. If lash exists, repeat steps 1 - 4 .
6.
CAUTION: Maintain grease in the sector shaft bearing through the grease fitting
in the housing using only a hand-operated grease gun. Add grease
until it begins to extrude past the dirt and water seal. Do not use a
power grease gun because it will supply grease too quickly. This can
adversely affect the high-pressure seal and contaminate the
hydraulic fluid.

If the adjustment was done with the steering gear on the vehicle, connect the steering sector shaft arm
drag link. If the steering gear was removed from the vehicle, install the steering gear. See STEERING
GEAR under REMOVAL & INSTALLATION.

REMOVAL & INSTALLATION

DAMPER

NOTE: The procedure for the Super Duty F250, F350 4x2 steering damper is similar.

Removal (F250/350, 4WD, F450/F550)

1. Position and lock the wheels in the straight-forward position. Raise and support the vehicle.
2. Remove the bolts and nuts. See Fig. 49 .
3. To install, reverse removal procedure. Tighten all fasteners to specification. See TORQUE
SPECIFICATIONS .

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Fig. 49: Removing Damper Bolts & Nuts

Courtesy of FORD MOTOR CO.

INNER TIE ROD

NOTE: Replace the tie rod end if the ball stud is loose in the socket or the tie rod end is
bent. Replace the front suspension steering ball stud dust seal if any nicks,
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cuts or tears are present. Do not attempt to straighten a tie rod end.

Removal & Installation (F250/F350 & 4X2)

1. Position and lock the wheels in the straight-forward position. Raise and support the vehicle.
2. Loosen the adjusting sleeve clamp. See Fig. 50 .

Fig. 50: Loosening Adjusting Sleeve Clamp

Courtesy of FORD MOTOR CO.

3. Remove the cotter pin and castellated nut. See Fig. 51 . Discard the cotter pin.

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Fig. 51: Removing Castle Nut

Courtesy of FORD MOTOR CO.

4. Disconnect the tie rod end. Use the Steering Arm Remover (211-003). See Fig. 52 .

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Fig. 52: Removing Tie Rod End

Courtesy of FORD MOTOR CO.

5. Remove the tie rod end. Note the number of turns required to remove the tie rod end.
6. To install, reverse removal procedure. Tighten all fasteners to specification. See TORQUE
SPECIFICATIONS . Check the toe-in and clear vision settings. See SPECIFICATIONS &
PROCEDURES -- TRUCKS article in WHEEL ALIGNMENT.

Removal & Installation (F250/350, 4WD, F450/F550)

NOTE: Replace the tie rod end if the ball stud is loose in the socket or the tie rod end is
bent. Replace the front suspension steering ball stud dust seal if any nicks,
cuts or tears or present. Do not attempt to straighten a bent tie rod end.

1. Position and lock the wheels in the straight-forward position.

2. Remove the right front wheel.
3. Loosen the adjusting sleeve clamp.
4. Remove the cotter pin and castellated nut. Discard the cotter pin.
5. Disconnect the tie rod end. Use the Steering Arm Remover. See Fig. 53 .

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Fig. 53: Removing Tie Rod End

Courtesy of FORD MOTOR CO.

6. Remove the tie rod end. Note the number of turns required to remove the tie rod end.
7. To install, reverse removal procedure. Tighten all fasteners to specification. See TORQUE
SPECIFICATIONS . Check the toe-in and clear vision settings. See SPECIFICATIONS &
PROCEDURES -- TRUCKS article in WHEEL ALIGNMENT.

OUTER TIE ROD

NOTE: Replace the tie rod end if the ball stud is loose in the socket or the tie rod end is
bent. Replace the front suspension steering ball stud dust seal if any nicks,
cuts or tears are present. Do not attempt to straighten a tie rod end.

NOTE: The left hand tie rod end is shown below; the right hand tie rod end is similar.

Removal & Installation (4X2 F250/350)

1. Position and lock the wheels in the straight-forward position. Raise and support the vehicle.
2. Remove the wheel.
3. Loosen the adjusting sleeve clamp.
4. Remove the cotter pin and castellated nut. Discard the cotter pin.
5. Disconnect the tie rod end using the Steering Arm Remover. See Fig. 54 .
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Fig. 54: Removing Outer Tie Rod End (4X2 F250/350)

Courtesy of FORD MOTOR CO.

Removal & Installation (4WD F250/350 & F450/550)

1. Position and lock the wheels in the straight-forward position.

2. Remove the wheel.
3. Loosen the adjusting sleeve clamps.
4. Mark the steering damper position. Remove the nuts, washers, and two U-bolts. Position the steering
damper out of the way. See Fig. 55 .
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Fig. 55: Marking & Removing Steering Damper

Courtesy of FORD MOTOR CO.

5. Remove the cotter pin and castellated nut. Discard the cotter pin. See .

Fig. 56: Removing Cotter Pin & Castellated Nut

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Courtesy of FORD MOTOR CO.

6. Disconnect and position the tie rod end out of the way. Use the Steering Arm Remover. See Fig. 53 .
7. Remove the cotter pin and castellated nut. Discard the cotter pin.
8. Disconnect the tie rod end. Use the Steering Arm Remover.
9. Remove the tie rod end. Note the number of turns required to remove the tie rod end.
10. Remove the adjusting sleeve clamp.
11. To install, reverse removal procedure. Tighten all fasteners to specification. See TORQUE
SPECIFICATIONS . Check the toe-in and clear vision settings. See SPECIFICATIONS &
PROCEDURES -- TRUCKS article in WHEEL ALIGNMENT.

Removal & Installation (Motorhome)

NOTE: Replace the front wheel spindle tie rod if the ball stud is loose in the socket or
the front wheel spindle tie rod is bent. Replace the front suspension steering
ball stud dust seal if any nicks, cuts or tears are present. Do not attempt to
straighten a bent front wheel spindle tie rod. The right front wheel spindle tie
rod is shown; the left front wheel spindle tie rod is similar.

1. Remove the wheel.

2. Loosen the adjusting sleeve clamp. See Fig. 57 .

Fig. 57: Removing Adjusting Sleeve Clamp

Courtesy of FORD MOTOR CO.
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3. Remove the cotter pin and castellated nut. Discard the cotter pin.
4. Disconnect the front wheel spindle tie rod. Use the steering arm remover. See Fig. 58 .

Fig. 58: Removing Outer Tie Rod End (Motorhome)

Courtesy of FORD MOTOR CO.

5. Remove the front wheel spindle tie rod. Note the number of turns required to remove the front wheel
spindle tie rod.
6. To install, reverse removal procedure. Tighten all fasteners to specification. See TORQUE
SPECIFICATIONS . Check the toe-in and clear vision settings. See SPECIFICATIONS &
PROCEDURES -- TRUCKS article in SUSPENSION.

POWER STEERING FLUID COOLER

Removal & Installation

1. Unclamp and disconnect the hoses. Drain the fluid into a suitable container. See Fig. 59 .

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Fig. 59: Removing Hoses From Cooler

Courtesy of FORD MOTOR CO.

2. Remove the bolts and the cooler. See Fig. 60 .

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Fig. 60: Removing Power Steering Cooler

Courtesy of FORD MOTOR CO.

3. To install, reverse the removal procedure. If a new cooler is being installed, install the hoses on the new
cooler. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS

POWER STEERING PUMP

Removal & Installation (5.4L & 6.8L Engine)

1. Remove the power steering pump pulley. See POWER STEERING PUMP PULLEY .
2. Disconnect the high-pressure and return lines. See Fig. 61 .
3. Remove the bolts and the pump. See Fig. 62 .

Fig. 61: Disconnecting High Pressure & Return Lines

Courtesy of FORD MOTOR CO.

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Fig. 62: Removing Pump Mounting Bolts

Courtesy of FORD MOTOR CO.

4. To install, reverse the removal procedure. Tighten all fasteners to specification. See TORQUE
SPECIFICATIONS .
5.
NOTE: Although the pump has four mounting bolt holes, only three bolts are used
to mount the pump on the engine.

When connecting a fitting with a seal ring, a new ring must be installed. See Fig. 63 . Use the Seal
Replacer (211-D027) to install a seal ring over a fitting.
6. Fill, purge and leak check the system.

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Fig. 63: Locating Seal Ring

Courtesy of FORD MOTOR CO.

Removal & Installation (7.3L Diesel Engine)

1. Remove the accessory drive belt.

2. Remove the air inlet tube.
3. Remove the return hose. See Fig. 64 .
4. Place a pan under the power steering pump and drain the pump.
5. Remove the power steering pump pulley. See POWER STEERING PUMP PULLEY .
6. Disconnect the power steering high-pressure line.
7. Remove the bolts and detach the pump from the bracket. See Fig. 65 .

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Fig. 64: Removing Return Hose

Courtesy of FORD MOTOR CO.

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Fig. 65: Removing Power Steering Pump Bolts

Courtesy of FORD MOTOR CO.

8. Disconnect the power steering oil cooler return hose and remove the pump.
9. To install, reverse the removal procedure. Tighten all fasteners to specification. See TORQUE
SPECIFICATIONS .
10. When connecting a fitting with a seal ring, a new ring must be installed. See Fig. 63 . Use the seal
replacer to install a seal ring over a fitting.
11. Fill and leak check the power steering system.

Removal & Installation (Motorhome Chassis)

1. Drain the power steering reservoir.

Install the power steering pump pulley. See Fig. 72 . Inspect the pulley for paint marks in the web area
near the hub. If there are two paint marks, discard the pulley. If there is no paint or one paint mark, use a
paint pencil to mark the web area of the pulley near the hub. Use the special tool. Tighten all fasteners to
specification. See TORQUE SPECIFICATIONS .
5. Lower the vehicle.
6. Rotate the belt tensioner and position the drive belt over the power steering pump pulley.

Fig. 72: Installing Pump Pulley (CIII & Motorhome Pumps)

Courtesy of FORD MOTOR CO.

RESERVOIR

Removal & Installation

1. Remove the fluid from the reservoir using a suction gun.

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2. Remove the attaching screws. See Fig. 73 .

3. Disconnect the hoses. See Fig. 74 .
4. To install, reverse the removal procedure. Tighten all fasteners to specification. See TORQUE
SPECIFICATIONS .
5. Fill and leak check the system.

Fig. 73: Removing Reservoir Attaching Nuts

Courtesy of FORD MOTOR CO.

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Fig. 74: Removing Reservoir Hoses

Courtesy of FORD MOTOR CO.

SECTOR SHAFT ARM DRAG LINK

NOTE: Replace the steering sector shaft arm drag link if the ball stud is loose in the
socket or the steering sector shaft arm drag link is bent. Replace the front
suspension steering ball stud dust seal if any nicks, cuts or tears are present.
Do not attempt to straighten a steering sector shaft arm drag link.

Removal & Installation (4X2 F250/350)

1. Position and lock the wheels in the straight-forward position. Raise and support the vehicle.
2. Loosen the adjusting sleeve clamps.
3. Remove the cotter pin and castellated nut. Discard the cotter pin.
4. Disconnect and position the tie rod end out of the way. Use the Steering Arm Remover.See Fig. 52 .
5. Remove the cotter pin and castellated nut. Discard the cotter pin.
6. Disconnect the steering sector shaft arm drag link. Use the Steering Arm Remover (211-003).See Fig.
82 .
7. Remove the steering sector shaft arm drag link. Note the number of turns required to remove the steering
sector shaft arm drag link.
8. Remove the adjusting sleeve clamp.
9. To install, reverse removal procedure. Tighten all fasteners to specification. See TORQUE
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SPECIFICATIONS . Check the toe-in and clear vision settings. See SPECIFICATIONS &
PROCEDURES -- TRUCKS article in WHEEL ALIGNMENT.

Removal & Installation (4WD F250/350 & F450/550)

NOTE: Replace the steering sector shaft arm drag link if the ball stud is loose in the
socket or the steering sector shaft arm drag link is bent. Replace the front
suspension ball stud dust seal if any nicks, cuts or tears are present. Do not
attempt to straighten a steering sector shaft arm drag link.

1. Position and lock the wheels in the straight-forward position. Raise and support the vehicle.
2. Loosen the adjusting sleeve clamp.
3. Remove the cotter pin and castellated nut. Discard the cotter pin.
4. Separate the steering sector shaft arm drag link.See Fig. 82 .
5. Remove the steering sector shaft arm drag link. Note the number of turns required to remove the steering
sector shaft arm drag link. See Fig. 75 .
6. To install, reverse removal procedure. Tighten all fasteners to specification. See TORQUE
SPECIFICATIONS . Check the toe-in and clear vision settings. See SPECIFICATIONS &
PROCEDURES -- TRUCKS article in WHEEL ALIGNMENT.

Fig. 75: Removing Steering Sector Shaft Arm Drag Link

Courtesy of FORD MOTOR CO.

Removal & Installation (Motorhome)

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NOTE: Replace the steering gear sector shaft arm if it is bent. If the steering gear
sector shaft arm is bent, check remainder of the steering linkage system for
signs of damage. Replace any damaged steering linkage parts as required. Do
not attempt to straighten the steering gear sector shaft arm or any other
steering linkage components.

1. Remove the cotter pin and castellated nut. Discard the cotter pin.
2. Disconnect the steering sector shaft arm drag link. Position the steering sector shaft arm drag link out of
the way. Use the steering arm remover.See Fig. 76 .

Fig. 76: Disconnecting Steering Sector Shaft Arm Drag Link

Courtesy of FORD MOTOR CO.

3. Remove the nut and bolt.

4.
CAUTION: Do not use heat or pound on the steering gear sector shaft arm or
sector shaft as damage can result. These components must be
replaced rather than repaired if they are damaged.

Remove the steering gear sector shaft arm. Use the steering arm remover.
5. To install, reverse removal procedure. Tighten all fasteners to specification. See TORQUE
SPECIFICATIONS . Check the toe-in and clear vision settings. See SPECIFICATIONS &
PROCEDURES -- TRUCKS article in WHEEL ALIGNMENT.

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SPINDLE STEERING ARM (MOTORHOME)

Removal & Installation

NOTE: The drag link spindle steering arm is shown in this procedure, the LH and RH
spindle steering arms are similar.

1. Remove the cotter pin and castellated nut. Discard the cotter pin.
2. Disconnect the steering sector shaft arm drag link. Use the steering arm remover.
3. Remove the cotter pin and castellated nut. Discard the cotter pin.
4. Remove the spindle steering arm. See Fig. 77 .

Fig. 77: Removing The Spindle Steering Arm

Courtesy of FORD MOTOR CO.
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5. Remove the key. See Fig. 78 .

Fig. 78: Removing Spindle Arm Key

Courtesy of FORD MOTOR CO.

6.
NOTE: The spindle hole is slotted to align the spindle steering arm with the front
wheel spindle. Make sure the key is flush with the face the of the slot face
of the spindle steering arm.

To install, reverse removal procedure. Tighten all fasteners to specification. See TORQUE
SPECIFICATIONS . Check the toe-in and clear vision settings. See SPECIFICATIONS &
PROCEDURES -- TRUCKS article in WHEEL ALIGNMENT.

STEERING GEAR

Removal & Installation (All Except Motorhome Chassis)

1. Remove the air cleaner assembly.

2. On the 7.3L, loosen the clamps and remove the air cooler outlet duct. See Fig. 79 . Press the brake pedal
several times to discharge the accumulator.
3. On all models, disengage the steering coupling shield from the line fitting and slide upwards on the
steering shaft.
4. Remove the pinch bolt. See Fig. 80 . Turn the steering wheel as necessary to access the bolt. Make sure
the steering column is locked.

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Fig. 79: Removing Air Cooler Duct

Courtesy of FORD MOTOR CO.

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Fig. 80: Removing Pinch Bolt

Courtesy of FORD MOTOR CO.

5.
CAUTION: During installation, do not overtighten the fittings.

Disconnect the lines. See Fig. 81 .

Fig. 81: Removing Fluid Lines

Courtesy of FORD MOTOR CO.

6. Raise the vehicle.

12. To install, reverse the removal procedure. Tighten all fasteners to specification. See TORQUE
SPECIFICATIONS . Using the special tool, install new seal rings on the power steering hose fittings.
13. Fill and leak check the system.
14. On 7.3L, bleed the hydro-boost system. See BLEEDING under LUBRICATION.

Removal & Installation (Motorhome Chassis)

Fig. 91: Centering Steering Gear

Courtesy of FORD MOTOR CO.

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Fig. 95: Removing Sector Shaft Adjustment Screw

Courtesy of FORD MOTOR CO.

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Fig. 96: Removing Sector Shaft Housing Cover

Courtesy of FORD MOTOR CO.

8. Remove the valve housing bolts and the identification tag. See Fig. 97 .
9. Remove the valve housing and piston assembly. See Fig. 98 .

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Fig. 97: Removing Valve Housing Bolts & Identification Tag

Courtesy of FORD MOTOR CO.

Fig. 98: Removing Valve Housing & Piston Assembly

Courtesy of FORD MOTOR CO.
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10. Remove and discard the gasket. See Fig. 99 .

11. Remove the ball bearings. Remove the bolts. Remove the steering gear ball return guide clamp. Remove
the steering gear ball return guide. Rotate the piston over a container to collect the 28 steering gear worm
balls. See Fig. 100 .

Fig. 99: Removing Gasket

Courtesy of FORD MOTOR CO.

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Fig. 100: Removing Ball Bearings

Courtesy of FORD MOTOR CO.

12. Remove the input shaft valve and housing assembly from the piston. See Fig. 101 .

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Fig. 101: Removing Input Shaft Valve & Housing From Piston
Courtesy of FORD MOTOR CO.

13. Remove and discard the seal.

14. Install the valve housing in the Bench Mounted Holding Fixture (307-003) and loosen the setscrew. See
Fig. 102 .
15. Use Adjuster and Lock Nut Wrench (211-012) to remove the race nut. See Fig. 103 .

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Fig. 102: Removing Valve Housing Set Screw

Courtesy of FORD MOTOR CO.

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Fig. 103: Removing Race Nut

Courtesy of FORD MOTOR CO.

16. Remove the power steering gear input shaft and control from the valve housing. See Fig. 104 .
17. Rotate the valve housing with the bench mounted holding fixture.
18. Use the Puller to remove the power steering gear input shaft seal dust seal. See Fig. 105 .

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Courtesy of FORD MOTOR CO.

15. Install the setscrew. See Fig. 102 .

16. Remove the valve housing from the bench mounted holding fixture and position the piston on the worm
gear.
17.
WARNING: Hold the ball return guides until the cap or clip is reinstalled. Failure
to hold the guides will result in a trapped ball or balls, which can
cause a vehicle accident. If the ball guides become unseated at any
time, remove all the balls and repeat the procedure.

Install the steering gear ball return guide on the piston.

18.
WARNING: The correct number of balls (28) are required for correct gear
operation. Count the balls and insert each carefully.

WARNING: To make sure the balls are correctly installed, rotate the steering
gear input worm gear and rack from one end of travel to the other

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without allowing the poppet adjuster to contact the valve housing or

moving the valve housing pilot face more than 69.1 mm (2-3/4
inches) from the input end of the rack piston. If the steering gear
input worm gear and rack cannot be rotated, reinstall the balls. If a
steering gear is installed with a steering gear input worm gear and
rack that cannot rotate, the steering gear will not function correctly
and steering and gear failure can result.

Rotate the piston while holding the steering gear ball return guide and install the 28 ball bearings into the
opening in the ball guide. See Fig. 100 .
19. Install the steering gear ball return guide clamp. Position the steering gear ball return guide clamp. Install
the bolts.
20. Install a new gasket.
21. Lubricate and install the seal on the piston. See Fig. 114 . Use Multi-Purpose Grease meeting Ford
specifications ESB-M1C93-B and ESR-M1C159-A.

Fig. 114: Installing Piston Seal

Courtesy of FORD MOTOR CO.

22. Make sure to align the oil passages in the steering gear housing. Install the piston assembly into the
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steering gear housing.

23. Rotate the teeth so they are on the same plane as the steering gear sector shaft.
24. Loosely install the valve housing bolts and the identification tag, if so equipped. See Fig. 97 .
25. Lubricate the O-ring on the sector shaft housing cover. Use Multi-Purpose Grease meeting Ford
specifications ESB-M1C93-B and ESR-M1C159-A.
26. Rotate the housing clockwise and install the sector shaft into the sector shaft housing.
27. The sector shaft locknut will be tightened during the steering gear meshload adjustment. Install the sector
shaft locknut.
28. Loosely install the sector shaft housing bolts. Install the sector shaft and housing assembly.
29. Tighten sector shaft housing bolts and valve housing bolts to specification. See TORQUE
SPECIFICATIONS .
30. Adjust the steering gear meshload. See XR 50 Steering Gear .

STEERING GEAR (MOTORHOME CHASSIS)

CAUTION: Do not clamp against the body of the housing as this can damage the
housing and cause difficulties during the disassembly and assembly
procedures. If mounting boss or flange is not accessible, fabricate and
attach a mounting plate to the housing mounting bosses.

Courtesy of FORD MOTOR CO.

10.
CAUTION: Do not damage the bore or DU bushing on the gears when removing
the seal.

Remove the seal. See Fig. 122 . Clamp the side cover in a vise. Place a standard 5/8-inch or 11/16-inch
3/8 drive socket in the center of the side cover. Pry the seal out with a rolling head pry bar using the
socket for support. Discard the seal and remove the socket.

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Fig. 122: Removing Side Cover Seal

Courtesy of FORD MOTOR CO.

11.
NOTE: The staked retainer must be locked in place and have no cracks. The
adjusting screw must rotate by hand with no perceptible end play (lash).

Inspect the sector shaft assembly for damaged adjusting screw threads. See Fig. 123 .
12. Replace adjusting screw if needed. If no damage was noted, go to next step.
13. Remove the relief valve cap/vent cap, O-ring and two-piece relief valve, if so equipped, from the valve
housing. See Fig. 124 . Discard the O-ring.

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Courtesy of FORD MOTOR CO.

17.
CAUTION: The set position of poppet seat and sleeve assemblies must not be
disturbed if the poppets are not going to be replaced or pushed in
during assembly.

Be prepared for more fluid drainage. Remove the rack piston subassembly. See Fig. 127 . Place the
assembly on a clean cloth.

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Fig. 127: Removing Rack Piston Subassembly

Courtesy of FORD MOTOR CO.

Courtesy of FORD MOTOR CO.

Courtesy of FORD MOTOR CO.

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Fig. 137: Removing Housing Trunnion Seal

Courtesy of FORD MOTOR CO.

29. Insert a screwdriver from the trunnion end of the housing and carefully push the seal and the spacer
washer out of the other end of the housing without damaging the sealing area or the spacer washer and
discard the seal. See Fig. 138 .

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Fig. 138: Removing Seal & Spacer From Housing

Courtesy of FORD MOTOR CO.

Inspection

1. Inspect the roller bearing in the housing for brinelling or spalling and inspect the retaining ring for
damage. See Fig. 139 . If installation of either part is required, go to STEERING GEAR HOUSING
ROLLER BEARING OR RETAINING RING (MOTORHOME) . If not, go to next step.

Fig. 139: Inspecting Roller Bearing

Courtesy of FORD MOTOR CO.

2. Inspect the following components for damage: Poppet fixed stop screw and washer, poppet adjusting
screw and sealing nut, pressed-in grease fitting, auto-bleed plug, manual bleed screw auxiliary port plugs
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and O-rings.
3. For additional inspection information, see STEERING GEAR COMPONENT INSPECTION
(MOTORHOME) .

Reassembly

1. Install a new dirt seal into the trunnion end of the sector shaft bore of the housing. Make sure the seal is
installed against the bearing and the lip of the seal faces outward.
2. Install the second retaining ring. Make sure the ring is firmly seated in the groove in the housing.
3.
NOTE: A dab of grease applied to the small diameter of the washer will hold it in
place during installation of the seal.

Install the washer into the side cover side of the housing seal bore with the small diameter piloted into the
retaining ring.
4. Assemble a new seal onto Bearing and Seal Tool, so the lip with the garter spring is toward the shoulder
of the tool.
5. Working from the side cover side of the housing, pilot the seal tool into the washer and bearing and press
with a force of 100-800 Lbs. (445-3,560 N.m) until the seal is seated against washer. See Fig. 140 .

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Fig. 140: Installing Seal (TAS40)

Courtesy of FORD MOTOR CO.

6. Liberally pack the area between the dirt seal and the pressure seal including roller bearing with High
Temperature Front Axle and Wheel Bearing Grease (E8TZ-19590-A) or equivalent meeting Ford
specification ESA-M1C198-A.
7. Lightly oil a new seal ring and assemble it in the valve housing mounting face groove. Oil the new seal
ring and assemble it in the valve housing mounting face groove.
8.
CAUTION: Do not overstretch these rings as you install them. Do not allow the
Teflon(R) seal ring to be twisted.

Install a new backup O-ring and then a new Teflon(R) seal ring on the rack piston. See Fig. 141 .

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Fig. 141: Installing Backup O-Ring & Teflon(R) Seal On Rack Piston (TAS40)
Courtesy of FORD MOTOR CO.

9. Place the rack piston in the housing piston bore with ball return guide holes up. Apply clean oil to the
housing cylinder bore.
10. Insert the worm shaft into the rack piston close to maximum depth, without the valve housing making
contact with the poppet stem.See Fig. 142 .

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Fig. 142: Inserting Worm Shaft Into Piston

Courtesy of FORD MOTOR CO.

11. Insert two 7/16-14 Ready Bolts through the valve housing bolt holes and tighten into housing to support
the worm shaft. Line up the rack piston ball guide holes with the worm ball track grooves by rotating the
input shaft. See Fig. 143 .

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Fig. 143: Lining Up Rack Piston Ball Guide Holes

Courtesy of FORD MOTOR CO.

12.
WARNING: Do not seat guides with a hammer. Damage to guides can result in
subsequent lockup or loss of steering.

CAUTION: If a new rack piston or a new input shaft, valve, worm subassembly is
being assembled, the balls removed from the unit must be discarded
and a service ball kit utilized. The balls in a service ball kit are sized
to function in the ball track guide path as altered by component
replacement. When using the service ball kit, the correct quantity of
service balls is 32.

NOTE: Compare the new guides with the guides removed from the gear; use the
ones that look the same. Left guides are copper-plated, right guides are
unplated.

Assemble the new ball return guide halves into the rack piston until seated and rotate the input shaft
slightly if necessary.
13.
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CAUTION: Hold the ball return guides until the cap or clip is reinstalled. Failure
to hold the guides will result in a trapped ball or balls. If the ball
guides become unseated at any time, remove all the balls and start
over.The correct number of balls are required for correct gear
operation. Count the balls and insert each carefully.

CAUTION: Do not allow the valve housing to contact the poppet adjuster or
move more than 63.5 mm (2-1/2 inches) from the upper end of the
rack piston during these procedures as this could incorrectly preset
the poppet adjuster.

NOTE: Hold the ball return guides firmly in place during this entire procedure.

Install the balls into the gear. Insert as many of the steel balls as you can through the hole in the top of the
ball return guides. Rotate the input shaft to pull the balls down and around the ball track guide path.
Continue until the correct number of balls is in the ball track guide path.
14.
NOTE: If a ball return guide clip is used, install a new guide clip.

Line up the holes in the clip and on the piston making sure the clip is in complete contact with the piston.
Install the bolts and tighten to 19 ft. lbs. (25 N.m). Bend the tabs of the clip against the bolt heads.
15.
CAUTION: To ensure balls are correctly installed, rotate wormshaft from one
end of travel to other without allowing poppet adjuster to contact the
valve housing or moving valve housing pilot face more than 63.5 mm
(2-1/2 inches) from the input end of rack piston. If wormshaft cannot
be rotated, reinstall balls. If a gear is installed with a wormshaft that
cannot rotate, the gear will not function correctly and steering and
gear failure can result.

NOTE:

If the gear is equipped with a ball return guide cap, lubricate a new seal and install the seal in the groove
in the cap. See Fig. 130 . Install the cap so the seal makes full contact with the surface of the piston,
install two new cap bolts and tighten to specification.
16.
CAUTION: Do not damage the seal ring while installing the rack piston into the
housing. If the seal ring end of the rack piston enters the housing
first, the seal ring will be destroyed when the rack is removed. The
poppet seat and sleeve assemblies must not bottom against the
internal poppet stops in the steering gear until the gear is installed
on the vehicle and the poppet adjustment procedures are performed.

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NOTE: Apply clean oil to the Teflon(R) seal ring on the rack piston. Make sure
there is a space of 10-13 mm (3/8-1/2 inch) between the valve housing and
the poppet stem to prevent poppet contact at either end.

Remove the Ready Bolts, and push the rack piston assembly into the housing with the rack piston teeth
toward the sector shaft cavity. Line up the valve housing cylinder feed hole with the gear housing feed
hole. See Fig. 144 .

Fig. 144: Aligning Valve Housing Cylinder Feed Hole With Gear Housing Feed Hole
Courtesy of FORD MOTOR CO.

17. Install the four (lubricated) valve housing bolts into the housing. Tighten the bolts to specification. See
TORQUE SPECIFICATIONS .
18.
NOTE: If the gear is equipped with a relief valve, assemble a new O-ring on the
relief valve cap.

Assemble the small end of the tapered spring onto the pin on the relief valve cartridge and insert the
assembly (large end of tapered spring end first) into the relief valve cap cavity. Turn the relief valve cap
as assembled into the valve housing and tighten to specification.
19.
CAUTION: Bearing is sealed and will receive no lubrication from the hydraulic

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fluid in the gear. Failure to use the correct grease can result in
premature bearing wear.

Lubricate the DU bushing or the bearing assembly. For TAS40, lightly oil the DU bushing but do not
grease. See Fig. 145 .

Fig. 145: Lubricating DU Bushing Or Bearing Assembly

Courtesy of FORD MOTOR CO.

20. Grease and assemble a new seal onto Bearing and Seal Installation Tool so the side with the garter spring
is against the shoulder of the installation tool. Pilot the tool into the side cover with a force of 100-800
Lbs. (445-3,560 N.m) until it is seated against the bearing or bushing. See Fig. 146 .

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Fig. 146: Installing Sector Shaft Seal

Courtesy of FORD MOTOR CO.

21. Lubricate the sector shaft. For TAS40, lightly oil the short bearing area of the sector shaft but do not
grease.
22. Insert the sector shaft into the side cover subassembly and screw the sector shaft adjusting screw
counterclockwise into the side cover until the screw reaches solid height.
23. Rotate the adjusting screw clockwise one half turn so the side cover will rotate freely on the sector shaft.
24. Install the sector shaft adjusting screw jam nut onto the sector shaft adjusting screw a few threads. Final
adjustment will be made later.
25.
CAUTION: Do not weld or otherwise plug this hole in any permanent manner.
This is a safety vent which functions only if the side cover seal fails.
If the seal fails and the plug cannot vent, the steering gear can lock
up or otherwise function incorrectly.

Press the new vent plug into the hole provided in the side cover until the plug is bottomed.
26. Apply clean grease to the new side cover gasket to hold it in place and put the gasket on the side cover.
27.

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CAUTION: If the rack piston is not centered when the sector shaft is installed,
the gear travel will be severely limited in one direction.

Rotate the input shaft to position the rack piston so that the space between the second and third teeth is in
the center of the sector shaft opening. This will center the rack piston for the installation of the sector
shaft. See Fig. 147 .

Fig. 147: Centering Rack Piston

Courtesy of FORD MOTOR CO.

28.
CAUTION: If the sector shaft serrations are not correctly taped, the serrations
will damage the housing seal during assembly causing the seal to
leak.

NOTE: Clean off any old tape on the serrations of the sector shaft. Retape the
serrations and the bolt groove with one layer of masking tape.

Install the sector shaft and side cover assembly into the gear housing. Make sure the center tooth of the
sector shaft engages the center space (between the second and third teeth) of the rack piston. Make sure
the side cover gasket is correctly in place.
29.
NOTE: If side cover bolts must be replaced, use bolts of the same design, type

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and length as those removed. Do not use a substitute.

Install the special side cover bolts into the side cover and tighten them in the sequence shown. See Fig.
148 . Alternately tighten the bolts, in the sequence shown, until the cover contacts the housing.

Fig. 148: Side Cover Torque Sequence

Courtesy of FORD MOTOR CO.

30. Tighten dry side cover bolts to specification. See TORQUE SPECIFICATIONS .
31. Remove the tape from the sector shaft and pack the end of the housing trunnion area at the sector shaft
with Mobil Temp 1 or 2, High Temperature Front Axle and Wheel Bearing Grease (E8TZ-19590-A) or
equivalent meeting Ford specification ESA-M1C198-A. Apply the grease to a new trunnion dirt seal and
assemble it over the sector shaft and into the trunnion bore.
32.
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NOTE: Pack the end of the valve housing bore around the input shaft with High
Temperature Front Axle and Wheel Bearing Grease or equivalent meeting
Ford specification ESA-M1C198-A.

Apply more of the grease to the inside of a new dirt and water seal and install it over the input shaft and
seat it in the groove behind the serrations and against the valve housing.
33. Adjust the steering gear meshload. See TAS40 Steering Gear under ADJUSTMENTS & INSPECTION.

STEERING GEAR ADJUSTING SCREW & RETAINER (MOTORHOME)

Disassembly

Disassembly

NOTE: The following tools are available from Kent-Moore Tool Division, 29784 Little
Mack, Roseville, MI 48066. Poppet Adjusting Seat Tool (J36452-B).

1. If the poppet assemblies are to be removed for replacement or internally reset for fully automatic poppet
adjustment after reinstallation, place the rack piston in a soft-jawed vise.
2.
CAUTION: Poppet adjuster seat and sleeve assemblies are retained by Loctite
(R) applied to the threads, which makes the assemblies difficult to
remove.

Slide Poppet Adjusting Seat Tool over the seat of the poppet adjuster seat and sleeve assembly and
engage the tool in the slots in the threaded sleeve. Hit the end of the tool firmly four or five times with a
2-lb. hammer to loosen the Loctite(R). See Fig. 153 .

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Fig. 153: Removing Poppet Adjuster

Courtesy of FORD MOTOR CO.

3. With a ratchet applied to the tool, turn one adjuster seat and sleeve assembly out of the rack piston. If the
ratchet does not turn easily, strike Poppet Adjusting Seat Tool again with a hammer. If the engaging tangs
won't stay in place while loosening, it might be necessary to hold in place with an arbor press while
applying the loosening torque. See Fig. 154 . Discard the poppet seat and sleeve assembly.

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Fig. 154: Removing Adjuster Seat & Sleeve From Rack Piston
Courtesy of FORD MOTOR CO.

4. Remove the two poppets, spring, spacer rod, and push tube. See Fig. 155 .

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Thursday, November 09, 2006 7:09:22 PM Page 168 © 2004 Mitchell Repair Information Company, LLC.
2000 Ford Pickup F350 Super Duty
2000-01 STEERING Power Steering Systems - Excursion, Super-Duty & Motorhome Chassis

Fig. 155: Removing Poppets, Spring, Spacer Rod & Push Tube
Courtesy of FORD MOTOR CO.

5.
NOTE: Reset one poppet adjuster seat and sleeve assembly for automatic poppet
adjustment while it is in the rack piston if one adjuster seat and sleeve
assembly and the poppets, spring, spacer rod and push tube are removed.

Remove the remaining poppet seat and sleeve assembly as required.

6. Clean the threads on the poppet seat and sleeve assemblies. See Fig. 156 . Use a 7/16-20 UNF thread
chaser.

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Thursday, November 09, 2006 7:09:22 PM Page 169 © 2004 Mitchell Repair Information Company, LLC.
2000 Ford Pickup F350 Super Duty
2000-01 STEERING Power Steering Systems - Excursion, Super-Duty & Motorhome Chassis

Fig. 156: Cleaning Poppet Seat & Sleeve Threads

Courtesy of FORD MOTOR CO.

Reassembly

1. Screw the poppet seat and sleeve assembly loosely into its threaded hole in the rack piston for full thread
length with the slotted end in.
2.
NOTE: If one poppet seat and sleeve assembly was left in the rack piston, it can
be reset for automatic poppet adjustment by inserting a 9.52-mm (3/8-inch)
diameter x 152.4-mm (6-inch) drill rod down through the poppet seat hole
at the opposite end of the rack piston and against the adjuster seat to
press the seat in until it bottoms against the adjuster sleeve.

Press the adjuster seat into the sleeve using 500-2500 Lbs. (2,224-11,120 N.m) force until the shoulder on
the seat bottoms against the sleeve and remove the adjuster seat and sleeve assembly from the rack piston.
Repeat the procedure for the other poppet seat and sleeve assembly if removed.
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Thursday, November 09, 2006 7:09:22 PM Page 170 © 2004 Mitchell Repair Information Company, LLC.
2000 Ford Pickup F350 Super Duty
2000-01 STEERING Power Steering Systems - Excursion, Super-Duty & Motorhome Chassis

3.
CAUTION: Do not allow Loctite(R) or Locquic to get on the adjuster seat and
sleeve assembly. The poppets will not function correctly.

Carefully apply Locquic T primer to the threads in the poppet holes, and threads on the seat and sleeve
assemblies. Allow to dry for ten minutes, then carefully apply Loctite(R) RC680 to the same threads. See
Fig. 157 .

Fig. 157: Applying Loctite To Threads

Courtesy of FORD MOTOR CO.

4.
WARNING: Wear eye protection while assembling poppets, as spring-loaded
poppets can eject and cause eye injury.

Place the rack piston in a soft-jawed vise and turn one poppet adjuster seat and sleeve assembly (slotted
end out) into the poppet hole in one end of the rack piston.
5. From the other end of the poppet hole in the rack piston, install the following:
z One poppet

z Poppet spring

z Nylon Spacer Rod

z Push tube

z Other poppet

z Other poppet adjuster seat and sleeve assembly

See Fig. 158 .

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Thursday, November 09, 2006 7:09:23 PM Page 180 © 2004 Mitchell Repair Information Company, LLC.
2000 Ford Pickup F350 Super Duty
2000-01 STEERING Power Steering Systems - Excursion, Super-Duty & Motorhome Chassis

Fig. 167: Removing Input Shaft Seal

Courtesy of FORD MOTOR CO.

Inspection

1.
CAUTION: Input shaft, valve, worm assembly must not be disassembled further.
The components were a select fit at assembly and are available only
as part of this subassembly. If disassembled further, a new
subassembly must be installed.

Inspect the sealing areas of the input shaft and the valve. Check for nicks and run your fingernail edge
across the sealing surfaces to detect steps. Inspect for discoloration from excess heat. Inspect input shaft
ball-track grooves for brinelling or spalling. If any of these conditions exist, install a new input shaft,
valve, worm assembly, valve housing and balls. Also install a new rack piston if brinelling or spalling is
found.

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Thursday, November 09, 2006 7:09:23 PM Page 181 © 2004 Mitchell Repair Information Company, LLC.
2000 Ford Pickup F350 Super Duty
2000-01 STEERING Power Steering Systems - Excursion, Super-Duty & Motorhome Chassis

2.
NOTE: TAS40 alternate construction: if the spacer sleeve is damaged, install a
new input shaft, valve, worm subassembly and use a thick washer and
roller bearing only during reassembly.

Inspect the thrust bearing rollers for any deterioration and the thrust washers for brinelling, spalling, or
cracks. Install new components as necessary. See Fig. 168 .

Fig. 168: Inspecting Thrust Bearings & Thrust Washers

Courtesy of FORD MOTOR CO.

6. Lightly oil and assemble a new seal ring onto the input shaft and against the thick thrust washer to hold
the bearing components in place. See Fig. 172 .

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Thursday, November 09, 2006 7:09:23 PM Page 185 © 2004 Mitchell Repair Information Company, LLC.
2000 Ford Pickup F350 Super Duty
2000-01 STEERING Power Steering Systems - Excursion, Super-Duty & Motorhome Chassis

Fig. 172: Installing New Seal Ring Onto Input Shaft

Courtesy of FORD MOTOR CO.

7. Dip the input end of the input shaft, valve and worm assembly into oil up to the worm lead then assemble
the input shaft end of the assembly into the valve housing until it is firmly seated.
8. Apply oil and assemble the other thrust bearing and then the thin thrust washer over the ball groove end
of the worm and seat them against the shoulder of the input shaft, valve and worm assembly.
9.
NOTE: Be sure the valve housing, adjuster locknut and bearing adjuster threads
are clean and free of any staking burrs that would impede the locknut from
turning freely on the adjuster or the adjuster turning freely in the valve
housing.

Lightly oil a new O-ring and assemble it into the seal groove in the bearing adjuster. Oil and work a new
seal ring into the same groove and smooth it out.
10. Lightly oil and assemble the bearing adjuster over the worm and into the valve housing. Tighten the
adjuster to specification, using a torque wrench inserted in Adjuster Tool (J37070). See TORQUE
SPECIFICATIONS . This will seat the components. Back off adjuster one-quarter to one-half turn. See

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Thursday, November 09, 2006 7:09:23 PM Page 186 © 2004 Mitchell Repair Information Company, LLC.
2000 Ford Pickup F350 Super Duty
2000-01 STEERING Power Steering Systems - Excursion, Super-Duty & Motorhome Chassis

Fig. 173 .

Fig. 173: Installing Bearing Adjuster

Courtesy of FORD MOTOR CO.

11. With an inch-pound torque wrench on the input shaft, note the torque required to rotate the input shaft
360 degrees in each direction. See Fig. 174 . Tighten the bearing adjuster to increase the maximum torque
(as specified) at the input shaft over the specification previously noted in step 10 .

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Thursday, November 09, 2006 7:09:23 PM Page 187 © 2004 Mitchell Repair Information Company, LLC.
2000 Ford Pickup F350 Super Duty
2000-01 STEERING Power Steering Systems - Excursion, Super-Duty & Motorhome Chassis

Fig. 174: Checking Input Shaft Rotating Torque

Courtesy of FORD MOTOR CO.

12.
NOTE: When using a torque wrench in adjuster lock nut tool, the torque wrench
reading must be as specified.

Lightly oil and assemble a new locknut onto the bearing adjuster with radius (slightly rounded) side
down. See Fig. 175 . Tighten the locknut while holding the bearing adjuster in position established in step
11 with Bearing and Seal Tool (J37071).

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Thursday, November 09, 2006 7:09:23 PM Page 188 © 2004 Mitchell Repair Information Company, LLC.
2000 Ford Pickup F350 Super Duty
2000-01 STEERING Power Steering Systems - Excursion, Super-Duty & Motorhome Chassis

Fig. 175: Installing New Bearing Adjuster Locknut

Courtesy of FORD MOTOR CO.

13. Recheck the input shaft torque. It must match the torque measured in step 11 . Repeat steps 11 and 12 if
necessary.
14. Stake the valve housing into the clockwise-most corner of two opposing slots in the locknut. Stake the
locknut into the adjuster in two places (180 degrees apart) at the threaded area. Choose areas that have not
been previously staked.
15. After staking, the torque required to rotate the input shaft must be greater than the torque noted in step
11 . The torque value must not exceed the specified torque. Unstake and readjust if necessary.
16. Reposition the worm screw/valve housing subassembly in a soft-jawed vise, clamping tightly against the
valve housing, so that the worm screw is pointing sideways.
17. Apply clean grease to the outside and inside diameters (fill cavity between the lips) of the new input shaft
seal and assemble it, garter spring side first over the input shaft. Align the seal in the valve housing seal
bore.
18.
CAUTION: The input shaft seal must be square in the seal bore and installed to
the correct depth.

Assemble Input Seal Installer Tool, small diameter end first, over the input shaft and against the seal and
tap the tool until the tool shoulder is squarely against the valve housing. This will correctly position the

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Thursday, November 09, 2006 7:09:23 PM Page 189 © 2004 Mitchell Repair Information Company, LLC.
2000 Ford Pickup F350 Super Duty
2000-01 STEERING Power Steering Systems - Excursion, Super-Duty & Motorhome Chassis

seal in the housing bore just beyond the retaining ring groove. See Fig. 176 .
19. Remove any seal material that may have sheared off and is in the seal bore and retaining ring groove. See
Fig. 176 .
20. Insert the new retaining ring into its groove in the valve housing. See Fig. 176 .

Helpmelearn Repair Manuals

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Thursday, November 09, 2006 7:09:24 PM Page 194 © 2004 Mitchell Repair Information Company, LLC.
2000 Ford Pickup F350 Super Duty
2000-01 STEERING Power Steering Systems - Excursion, Super-Duty & Motorhome Chassis

Fig. 180: Pressing In New Roller Bearing

Courtesy of FORD MOTOR CO.

SPECIAL TOOLS
SERVICE TOOLS
Tool Number Description
J37464 Adjuster Lock Nut Tool
J37070 Adjuster Tool
J37071 Bearing & Seal Tool
023-R0007 or Equivalent Dial Thermometer 0-222° F
105-R0053 or Equivalent Handheld Automotive Meter
J37073 Input Seal Installer
308-001 (T58L-101-B) Pilot Bearing Remover
J36452-B Poppet Adjusting Seat Tool
211-F001 (014-00207) Power Steering Analyzer
211-044 (T77L-3576-A) Sector Shaft Seal Installer
211-003 Steering Arm Remover
211-S005 (T65P-3524-A) Steering Gear Bearing & Oil Seal Service Set

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Thursday, November 09, 2006 7:09:24 PM Page 195 © 2004 Mitchell Repair Information Company, LLC.
2000 Ford Pickup F350 Super Duty
2000-01 STEERING Power Steering Systems - Excursion, Super-Duty & Motorhome Chassis

418-F102 (007-0061) Tach Adaptor

211-D027 (D90P-3517-A) Teflon Seal Installer Set
307-003 (T57L-500-B) Transmission Holding Fixture
416-D002 (D95L-7559-A) Vacuum Pump
211-012 (T66P-3553-B) Worm Bearing Locknut Installer
416-D002 Vacuum Pump

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