replacing rack and pinion on 2003 ford taurus


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2005 Ford F 150 Drive Pinion Flange and Drive Pinion Seal REPAIR

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Filed Under (Ford) by admin on 23-02-2011

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Removal CAUTION: The color on the rear face of the drive pinion nut is critical to this repair. Use the same color new drive pinion nut for installation. If a new collapsible spacer must be installed for pinion bearing preload reduction, install the nut supplied with the new spacer or damage to the component may occur. 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02. 2. Remove the brake disc. For additional information, refer to Section 206-04. 3. Index-mark the driveshaft flange and pinion flange for correct alignment during installation. 4. Remove the 4 driveshaft flange bolts. 5. NOTE: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft centering socket yoke from the pinion flange. Pry only in the area shown with a suitable tool to disconnect the driveshaft centering socket yoke from the pinion flange. Using a suitable tool as shown, disconnect the driveshaft centering socket yoke from the pinion flange. ? Using mechanic’s wire, position the driveshaft aside. 6. Using a Nm (lb-in) torque wrench on the pinion nut, record the torque required to maintain rotation of the pinion gear through several revolutions. 7. Using the special tool to hold the pinion flange, remove and discard the pinion nut. 8. Index-mark the pinion flange in relation to the drive pinion stem to make sure of correct alignment during installation. 9. Using the special tool, remove the pinion flange. 10. Force up on the metal flange of the drive pinion seal. Install gripping pliers and strike with a hammer until the drive pinion seal is removed. Installation 1. Lubricate the new drive pinion seal with grease. 2. Using the special tool, install a new drive pinion seal. 3. Lubricate the pinion flange splines with axle lubricant. 4. NOTE: Disregard the scribe marks if a new pinion flange is being installed.

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2002 Ford F-150 Drive Pinion Flange Removal Installation

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Filed Under (Ford) by admin on 22-02-2011

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All vehicles 1. Raise and support the vehicle. For additional information, refer to Section 100-02. 2. NOTE: The rear wheels and brake drums/calipers must be removed to prevent brake drag during drive pinion bearing preload adjustment. Remove the wheel and tire assembly. For additional information, refer to Section 204-04. Vehicles with drum brakes 3. Remove the rear brake drums. For additional information, refer to Section 206-02. Vehicles with disc brakes 4. Remove the rear disc brake caliper. For additional information, refer to Section 206-04.  Wire the rear disc brake caliper aside. 5. Remove the rear brake disc. 6. Mark the driveshaft flange and pinion flange for correct alignment during installation. 7. Remove the four driveshaft bolts. 8. CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion flange pilot. Ne ver hammer on the driveshaft or any of its components to disconnect the yoke from the flange. Pry only in the area shown with a suitable tool to disconnect the yoke from the flange. Using a suitable tool as shown, disconnect the driveshaft centering socket yoke from the rear axle pinion flange. Position the driveshaft out of the way. 9. Install an inch-pound torque wrench on the pinion nut and record the torque required to maintain rotation of the pin ion through several revolutions. 10. CAUTION: After removal of the pinion nut, discard it. A new nut must be used for installation. Using the special tool, hold the pinion flange and remove the pinion nut. 11. Mark the pinion flange in relation to the drive pinion stem to make sure of correct alignment during installation. 12. Using the special tool, remove the pinion flange. Installation All vehicles 1. Lubricate the pinion flange splines with rear axle lubricant. 2. NOTE: Disregard the scribe marks if a new pinion flange is being installed. Align the pinion flange with the drive pinion shaft.

1999 Ford Taurus Steering Gear Base REMOVAL AND INSTALLATION

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Filed Under (Ford) by admin on 19-02-2011

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1. Open hood. 2. Disconnect battery ground cable (14301). Refer to Section 14-01. 3. From inside vehicle, remove nuts retaining steering column tube boot (3C611) to cowl panel. 4. Remove bolt retaining steering column intermediate shaft coupling (3A525) to steering column lower yoke (3N725) . 5. Position steering column tube boot out of the way. Remove pinch bolt retaining steering column intermediate shaft coupling to power rack and pinion steering gear and remove steering column intermediate shaft coupling . 6. Raise vehicle on a twin post hoist and remove front wheel and tire assemblies. 7. Remove exhaust system flex tube-to-dual converter Y-pipe attachment. Disconnect heated oxygen sensor wiring harness. Remove dual converter Y pipe (5F250) from vehicle. Dual Converter Y Pipe Removal 8. Support vehicle with jack stands under rear edge of front sub-frame (5C145). 9. Remove tie rod cotter pins and nuts, and remove tie rod end (3A130) from RH front wheel knuckle (3K185) and LH front wheel knuckle (3K186). 10. Remove tie rod end from front wheel spindle tie rod (3280) . Mark position of jam nut to maintain alignment. 11. Remove nuts from steering gear-to-front sub-frame retaining bolts. 12. Remove rear sub-frame-to-body retaining bolts. 13. Raise twin post hoist carefully until rear sub-frame (5R003) separates from body approximately 102 mm (4 inches). 14. Remove heat shield push-pin retainers from power steering hose bracket (3C510). Remove steering shaft U-joint shield (3F540). 15. Remove screw and power steering left turn pressure hose (3A714) from power steering hose bracket . Remove two screws and power steering hose bracket. 16. Remove LH stabilizer bar link (5K484). 17. Disconnect power steering pressure switch electrical connector. 18. Rotate power rack and pinion steering gear to clear bolts from front sub-frame and pull left to ease line fitting removal. 19. Place a drain pan under vehicle and remove hydraulic power steering pressure hose and power steering return hose from fittings on power rack and pinion steering gear. 20. Remove power rack and pinion steering gear assembly through LH wheel well. Installation 1. Install new Teflon® O-rings on both line connector assemblies as described under Quick Connect Power Steering Fitting—Seal Replacement. 2. Place steering gear retaining bolts in steering gear housing (3548). 3. Install power rack and pinion steering gear through LH wheel well. 4. Install power steering hose bracket and two screws. Tighten to 9-12 Nm (80-106 lb-in). 5. Install hydraulic power steering pressure hose and power steering return hose to fittings on power rack and pinion steering gear. Tighten hoses to 33-41 Nm (25-30 lb-ft). 6. Install power steering pressure hose and and screw. Tighten to 9-12 Nm (80-106 lb-in). 7. Connect power steering pressure switch electrical connector. 8. Position power rack and pinion steering gear into front sub-frame. 9. Install tie rod ends onto front wheel spindle tie rods . 10. Install push-pin retainers at top of heat shield. 11. Install tie rod end to RHfront wheel knuckle and LH front wheel knuckle. Install nuts and tighten to 47-63 Nm (35-46 lb-ft). Install new cotter pins. 12. Install LH stabilizer bar link. Tighten to 76.5-103.5 Nm (57-76 lb-ft).

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2003 Ford F-150 Front Drive Axle and Differential Exploded View

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Filed Under (Ford) by admin on 30-03-2011

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The axle housing assembly consists of a cast-aluminum center section, a removable cast-aluminum axle housing tube (3B210), and a differential housing cover (3N136). Both the axle housing tube and the differential housing cover use silicone sealant as a gasket. The hypoid-design gearset consists of an 8.8-inch ring gear (3A397) and a pinion gear (3N175). Two opposed tapered roller bearings support the drive pinion in the axle housing. A drive pinion collapsible spacer (4662), located on the pinion shaft, maintains pinion bearing preload. The pinion nut adjusts the preload. Differential bearing shims (4A451), located between the differential bearing cups (4221) and the axle housing, adjust the differential bearing preload and the ring gear backlash. The differential case (4205) is a one-piece design with two openings to allow for assembly of the internal components and lubricant flow. Two opposed tapered roller bearings (differential bearings [4221]) support the differential case in the axle housing. Removable differential bearing caps (4224) retain the differential assembly in the axle housing. Inside the differential case, the differential pinion shaft (4211) supports two differential pinion gears (4215). The pinion gears engage the differential side gears (4236), to which the left axle shaft (3A381) and the axle cluster gear shaft (7L253) are splined. The differential pinion shaft bolt retains the differential pinion shaft in the differential case. An embossed metal tag, bolted to the rear face of the RH axle tube, contains front axle identification information. CAUTION: Actuate the front drive axle with the wheels in a straight ahead position, and at light throttle only. A front axle actuator motor assembly (7G360), controlled by an instrument panel-mounted switch, actuates the front drive axle.

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ENGINE MISFIRE 2003-2004 Mustang, 1999-2004 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2003-2004 Marauder

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Filed Under (Ford) by admin on 11-05-2010

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Some 1999-2004 Navigator, 2002-2003 Blackwood, 2003-2005 Aviator, 2003-2004 Marauder and 2003-2004 Mustang vehicles built before 12/19/2004 equipped with 4.6L 4V/5.4 4V engine may exhibit a runs rough, lacks power, and engine misfire, prompted by a MIL light and DTC codes P0301, P0302, P0303, P0304, P0305, P0306, P0307, P0308, and P0316. ACTION Diagnose engine for engine misfire concern. If diagnostics determine an engine misfire which is characterized by leakage through exhaust valve(s), only replace the affected cylinder head(s). SERVICE PROCEDURE

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