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

 

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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:

    Removal
    WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury ...

    Cleaning
    1. Fabricate a cleaning tool from a 1/8 inch diameter brazing rod. 2. Cut an abrasive pad from maroon colored 3M Scotch Brite with the dimensions corresponding to the coupling size. 3. Assemble the pad to the tool. 4. Coat the abrasive pad with PAG Refri ...

    Accelerator Cable Bracket - Supercharged Engine
    Removal and Installation 1. Disconnect the accelerator cable and speed control cable. 2. Depress the tabs and disconnect the accelerator cable and speed control cable from the accelerator cable bracket 3. Remove the bolts and the accelerator cable bracket ...