Lincoln F7AZ-3504-FDRM Gear Assembly - Steering

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For 2002 and earlier models, the removal process of the rack and pinion involves taking several steps. First, the stone shield is removed by unclipping a lock tab, allowing it to open into two halves for separation. The pressure and return lines on the rack and pinion are tagged for future identification and then disconnected, with the fluid line fittings and pinch bolt on the flex coupling clamp also removed. The Pitman arm is detached from the sector shaft, and the rack and pinion is supported and its attaching bolts removed to free it from the flex coupling. During installation, the flex coupling is positioned on the steering shaft assembly with the steering wheel spokes in a horizontal position. The rack and pinion input shaft is centered and inserted into the flex coupling clamp and frame side rail, and the rack and pinion mounting bolts are installed and tightened. The Pitman arm is placed back onto the sector shaft, and the Pitman arm nut is secured. The flex coupling-to-rack and pinion input shaft clamp bolt is installed and tightened, and the pressure and return lines are reconnected securely. The power steering system is then filled and bled. For 2003 and later models, the procedure varies slightly. After parking with the wheels straight ahead, the front wheel lug nuts are loosened, and the vehicle is raised and supported on jackstands with the parking brake applied. The intermediate shaft coupler's relationship to the rack and pinion input shaft is marked, and the pinch bolt is removed. A drain pan is placed under the rack and pinion, and the power steering pressure and return lines are unscrewed from the rack and pinion using a flare-nut wrench. The tie-rod ends are detached from the steering knuckles, and the rack and pinion is lowered from the vehicle. During installation, the rack and pinion mounting studs and nuts are tightened, along with the intermediate shaft coupler pinch bolt and wheel lug nuts. The power steering fluid level is checked and topped up if necessary, followed by bleeding the system and rechecking the fluid level.

For 2002 and earlier models, the removal process of the rack and pinion involves taking several steps. First, the stone shield is removed by unclipping a lock tab, allowing it to open into two halves for separation. The pressure and return lines on the rack and pinion are tagged for future identification and then disconnected, with the fluid line fittings and pinch bolt on the flex coupling clamp also removed. The Pitman arm is detached from the sector shaft, and the rack and pinion is supported and its attaching bolts removed to free it from the flex coupling. During installation, the flex coupling is positioned on the steering shaft assembly with the steering wheel spokes in a horizontal position. The rack and pinion input shaft is centered and inserted into the flex coupling clamp and frame side rail, and the rack and pinion mounting bolts are installed and tightened. The Pitman arm is placed back onto the sector shaft, and the Pitman arm nut is secured. The flex coupling-to-rack and pinion input shaft clamp bolt is installed and tightened, and the pressure and return lines are reconnected securely. The power steering system is then filled and bled. For 2003 and later models, the procedure varies slightly. After parking with the wheels straight ahead, the front wheel lug nuts are loosened, and the vehicle is raised and supported on jackstands with the parking brake applied. The intermediate shaft coupler's relationship to the rack and pinion input shaft is marked, and the pinch bolt is removed. A drain pan is placed under the rack and pinion, and the power steering pressure and return lines are unscrewed from the rack and pinion using a flare-nut wrench. The tie-rod ends are detached from the steering knuckles, and the rack and pinion is lowered from the vehicle. During installation, the rack and pinion mounting studs and nuts are tightened, along with the intermediate shaft coupler pinch bolt and wheel lug nuts. The power steering fluid level is checked and topped up if necessary, followed by bleeding the system and rechecking the fluid level.

All models except 1982 through 1987 Continentals and 1984 through 1992 Mark Vlls require the following steps for removal and installation of the rack and pinion. To remove the stone shield, unclip the lock tab and separate the shield into two halves. Tag the pressure and return lines on the rack and pinion and disconnect them. Remove the pinch bolt securing the flexible coupling to the rack and pinion. Raise the vehicle and remove the nut attaching the Pitman arm to the sector shaft. Remove the Pitman arm from the sector shaft. Support the rack and pinion and remove the rack and pinion attaching bolts. Work the gear free of the flex coupling and remove it. To install the rack and pinion, slide the flex coupling into place on the steering shaft assembly. Center the rack and pinion input shaft and slide it into the flex coupling clamp and into place on the frame side rail. Install the rack and pinion mounting bolts. Install the Pitman arm on the sector shaft and tighten the nut. Install the flex coupling-to-rack and pinion input shaft clamp bolt. Connect the pressure and return lines to the rack and pinion. Fill the reservoir and turn the steering wheel from stop to stop. Recheck the fluid level and start the engine to inspect for fluid leaks. Bleed the power steering system. For 1982 through 1987 Continentals and 1984 through 1992 Mark Vlls, additional steps include raising the front of the vehicle and supporting it on jackstands. Place a drain pan under the rack and pinion and remove the power steering pressure and return lines. Mark the relationship of the intermediate shaft flexible coupling to the rack and pinion input shaft. Separate the tie-rod ends from the spindle arms. Support the rack and pinion and remove the rack and pinion-to-frame mounting nuts and bolts. Lower the unit, separate the intermediate shaft from the rack and pinion input shaft, and remove the rack and pinion from the vehicle. To install, raise the rack and pinion into position and connect the intermediate shaft. Install the mounting bolts and washers and tighten the nuts. Connect the tie-rod ends to the steering knuckle arms. Install the intermediate shaft pinch bolt and tighten it. Connect the power steering pressure and return hoses to the rack and pinion and fill the power steering pump reservoir with the recommended fluid. Lower the vehicle and bleed the steering system.