How to Install the Power Steering Gear Box on a 2004 F-250

Replacing the power steering gearbox on a 2004 Ford F-250 super duty truck is a challenging procedure. There are safety issues to be followed closely for a proper installation. The air bags clock spring behind the steering wheel is a major concern. The steering wheel must be locked in the straight-ahead position and its position maintained when the gear is removed. Turning the steering wheel will unwind the expensive clock spring, which would break and keep the air bag from deploying.

Instructions

Removal

1

Place the drain pan under the steering gear box. Loosen the air duct clamps with the flat-head screwdriver and remove the air duct. Remove the air filter element and housing as well, using a socket and a ratchet to gain better access to the steering gear. Loosen the clamp on the steering column to steering gear coupler cover with a socket and a ratchet. Push the cover up the column toward the firewall.

2

Remove the pinch bolt in the steering coupler, using a socket and a ratchet. If it is necessary to rotate the coupler to access the bolt, turn the key to release the steering wheel and turn the wheel a few degrees. Turn the key off so the steering wheel is locked in place. Remove the pinch bolt. Turn the key on and rotate the wheel back to the straight ahead position. Do not rotate the steering wheel more than the few degrees back to center, and lock it in place by turning the key off.

3

Pry the coupler off the short steering gear input shaft using the screwdriver. Remove both power steering hoses using a wrench. Discard the O-ring on the end of the hose. Drain the fluid into the drain pan.

4

Raise the truck and place a jack stand under each side of the frame just behind the front wheels. Lower the truck so it rests on the stands. Mark the steering gear box directly over the pitman arm for reference to be transferred to the new gear. The pitman arm must be installed in the exact same location on the new pump as it was on the old. Mark the bottom of the pitman arm as well to signify which side is down. They are usually bent and can be installed either way, although only one way works properly.

5

Remove the cotter pin from the end of the pitman arm stud that secures the drag link, using wire cutters. Remove the nut on the drag link. Place the tie rod remover tools fork between the pitman arm end and the drag link. Hit the end of the tool until the drag link separates from the pitman arm stud.

6

Remove the retaining nut under the pitman arm, using a socket and a ratchet. Install the pitman arm puller and remove the pitman arm from the sector shaft. Remove the three bolts securing the steering gearbox to the frame, using a socket and a ratchet. Be careful when removing the last bolt as the gearbox is heavy enough to make it hard to hold with one hand. Remove the gearbox.

Installation

7

Locate the center position in the gearbox so it has equal travel in both directions. Place a rag over the gearbox coupler shaft. Place a vise grips on the shaft very lightly. Do not make it tight or it will destroy the shafts splines. Use just enough pressure to turn the gearbox. Turn the gearbox all the way to the stop in either direction. Turn it in the opposite direction until it stops, while counting the number of turns required from one stop to the next. Split the number in half, for example: if it takes 4 1/2 turns stop to stop, divide that number by two to get 2 1/4 turns. In this example, you would turn the shaft 2 1/4 turns back to center the gearbox.

8

Position the old gearbox next to the new one and transfer the white mark to the same position on the new gearbox. Install the new gearbox and torque the frame bolts to 59 foot-pounds. Install the pitman arm on the sector shaft in alignment with the white mark. Torque the pitman arm nut to 199 foot-pounds.

9

Lift the drag link and install it on the end of the pitman arm by pushing it up on the pitman arm stud. Install the nut and torque it to 66 foot-pounds. Install a new cotter pin. Pull the steering coupler down and push it on the gearboxs input shaft. Install the pinch bolt and torque it to 36 foot-pounds.

10

Install new O-rings on the ends of both power steering hoses. Install the hoses and torque them to 26 foot-pounds. Pull the coupler cover down and tighten the clamp with a socket and a ratchet. Install the air cleaner housing and air duct.

11

Fill the power steering reservoir with Mercron universal transmission fluid. Start the truck and slowly turn the steering wheel all the way to the stop in both directions several times to remove all air from the system. The pump will buzz for a few moments until you remove all the air. With the engine running, check the power steering reservoir for foamy fluid, indicating escaping air. Continue to rotate the steering wheel back and forth until all the air and noise are gone.

12

Check and top off the power steering reservoir as necessary. Install the cap on the reservoir. Lift the truck and remove the jack stands. Lower the truck.