Ford Mustang (1999-2004) Service Manual: Gear (Removal and Installation)

Special Tool(s)

Teflon Seal Replacer Set 211-D027 (D90P-3517-A) or Equivalent
Tie Rod End Remover 211-001 (TOOL-3290-D)

Removal

1. Turn the steering wheel as necessary to position the wheels in the straight-ahead position. Do not lock the steering column.

2. Raise and support the vehicle.

3. Remove the front wheels and tires.

4. Remove the cotter pin and nut. Discard the cotter pin.

Gear

5. Using the special tool, disconnect the tie-rod end.

Gear

6. Rotate the steering column intermediate shaft as necessary to access the pinch bolt. Remove and discard the pinch bolt.

Gear

7. Lower the vehicle.

8. Turn the steering wheel back to the straight-ahead position. Turn the ignition key to the locked position.

9. CAUTION: Do not rotate the steering wheel when the lower steering column shaft is disconnected, or damage to the air bag sliding contact will result.

Disconnect the steering column intermediate shaft coupling (3A525).

Gear

10. Remove the nuts, washers and bolts. Position the steering gear (3504) forward.

Gear

11. Disconnect the power steering hoses. Remove and discard the seal rings.

  • Plug or cap the power steering hoses and steering gear ports to prevent damage and the entry of foreign material.

Gear

12. Remove the steering gear.

Installation

1. To install, reverse the removal procedure.

  • Using the special tool, install a new seal ring.
  • Install a new pinch bolt.

Gear

 

Gear

 

Gear

 

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Gear

2. Fill and leak check the power steering system.

    Cooler - Fluid
    Removal 1. Raise and support the vehicle. 2. Disconnect the power steering hoses. 3. Remove the bolt and routing bracket. 4. Remove the bolts and the power steering fluid cooler. Installatio ...

    Gear (Disassembly and Assembly)
    Special Tool(s) Head Mounting Fixture 303-D041 (D83L-500-B1) or Equivalent Inner Tie Rod Socket Tool 211-D025 (D90P-3290-A) or Equivalent Steering Gear Holding Fixtur ...

    Other materials:

    Manual Transmission
    The T5OD 5-speed transmission: fifth speed gear functions as an overdrive gear. forward gears are synchronized and helical cut. shift interlock system prevents the engagement of more than one gear. Transmission, Manual Five-Speed   T ...

    Inspection and Verification
    1. The keyless entry system is a generic electronic module (GEM). 2. Verify the customer concern by using the remote transmitters to operate the keyless entry system. 3. Visually inspect for the following obvious signs of mechanical and electrica ...

    Tracer Dye Leak Detection
    Special Tool(s) 120 Watt 110 Volt UV Lamp 20C 164-R0721 or equivalent NOTE: Ford Motor Company vehicles are produced with a permanent leak tracer dye incorporated into the A/C system. The location of leaks can be pinpointed by the bright ye ...