Placing column onto replaced rack au falcon

no info generic answer no one seems to have done one yet as per youtube

If your steering wheels turns all the way but your wheels don't:
This would have to be either a broken rack and pinion(steering gear) or the shaft between the rack and pinion and the steering wheel would have to be broken. This would need to be visually inspected to be sure which is the problem.

I would have to guess that your steering wheel is no longer connected to the rack (as opposed to something in the rack breaking). My best guess is that your steering column shaft snapped.

They can be replaced, and the necessary parts are sold, but it's not the easiest thing in the world to replace.

stick your head down under the dash on the driver's side where the brake and gas pedals are, and look up at the steering shaft (can't miss it). Now turn the steering wheel. Does that shaft turn?

Sounds like something broke. Either in the steering column or the linkage between the column and the rack and pinion. Take it to a reliable repair shop for examination and repair. Best case scenario is the linkage between the column and rack and pinion came apart but I have never heard of it happening. Worse case scenario you need a new column or rack and pinion. You don't say what make and model of your vehicle is.

1. Jack the car onto stands and remove the front wheels.
2. Remove the drivers seat and the lower dash covers over the pedals.
3. THIS STEP IS VERY IMPORTANT. Place the steering wheel at center, and remove the key, to lock the steering column for the rest of the job. If you don't do this you WILL destroy the air bag clock spring under the steering wheel, and they are VERY expensive and fiddly to install.
4. Move the carpet / mats as necessary and undo the splined connection on the pinion shaft.
5. Drain the power steering fluid and disconnect the hoses from the rack. The hose connections will be very tight.
6. Undo the tie rod ends, and the two clamps that secure the rack to the frame. With some wiggling the rack can be removed.

Procedure on replacing the inner tie rod ends:


1) Raise and safely support the vehicle.

2) Remove the front wheel/tire assembly.

3) Clean the steering rod between the steering boot and outer tie rod end lock nut with a suitable penetrating lubricant and a clean cloth or shop towel.

4) Loosen the outer tie rod end locking nut 1/8 turn.

5) Loosen the steering boot clamp(s), and slide the small clamp off the boot.

6) Carefully loosen the boot and slide outward off the steering rack and onto the shaft to expose the inner steering rod mounting fastener.

7) If necessary, position the inner steering rack shaft in or out to allow for additional access.

8) Relieve the steering rod nut locking tab from the inner steering rack shaft, then loosen the steering rod ball socket nut 1 turn.

9) Matchmark the tie rod end to the threaded shaft.

10) Remove the cotter key and castle nut from the outer tie rod end threaded spindle, and using a tie rod end removal tool, remove the tie rod from the steering knuckle.

11) Hold the tie rod with a wrench, and remove the outer tie rod end from the threaded rod, counting the number of complete turns it takes to remove the tie rod end from the shaft. Write the number of turns on a piece of note paper.

12) Remove the tie rod end lock nut from the threaded steering shaft.

13) Slide the steering rack boot off the shaft.

14) Remove the inner steering rod ball socket nut from the inner steering rack shaft.

To install:

1) Inspect the tie rod end for looseness, and the steering rack boot and tie rod end boot for cracks deterioration or damage and replace as necessary.

2) Clean steering rack shaft and apply a light coating of Genuine Honda Power steering fluid as necessary.

3) Apply a medium strength locking agent to the threads where the inner steering rod ball socket mounts. Use a new locking washer and a new stop washer, and install the inner tie rod onto the steering rack shaft.

4) Tighten the inner tie rod end fastener by 58 ft. lbs. (78 Nm)

5) Peen the lock washer over the nut or onto the flat surface of the steering rack shaft.

6) Apply silicone grease to the outer circumference of the inner tie rod end ball socket, and onto the groove just outside of the socket.

7) Apply silicone grease to the inside of the small end of the steering rack boot, and slide the boot over the steering shaft and onto the rack and install the boot clamps. If the boot has air hose fittings make sure they are installed as removed.

8) Apply a light film of an anti-seize compound onto the threaded tie rod end, and install the tie rod end lock nut.

9) Install the tie rod end onto the tie rod, turning it in exactly the number of turns it took to remove it.

10) Install the tie rod end following the tie rod end installation procedure.

11) The balance of installation is the reverse of the removal procedure.

12) Check the front end alignment and adjust as necessary.

Hi, Aillathu,
The rack and pinion unit fits across from left to right....It is fitted onto the cross member....The pinion is fitted into the housing at almost right angles to the rack....The rack and pinion is a very positive steeling method, giving excellent response and usually good road feel....The unit consists of the rack which is fitted into the housing and joins the left and right wheels....and the pinion at more or less right angles to the rack...A leakage usually indicates worn oil seals which become damaged when a protective boots is broken....(The protective covers fitting onto the end of the rack housing)....The pinion is the part which attaches to the Steering column and the steering wheel....
If you're intending to do this job yourself, remember to pin punch 'match marks' onto the steering wheel and the top of the column before removing the nut. Next disconnect the steering fluid lines and drain the fluid into a container....(Don't forget to use goggles)
Jack the vehicle up and remove the front wheels....Turn the steering so that the tie rod ends can be loosened and removed from the housings (this will require a taper loosening tool)....removing them can also be achieved with a large hammer, but this method is not recommended!....Set the steering at straight ahead....Remove the joint attaching the pinion to the steering column....Once removed loosen the saddles holding the assembly onto the cross member and remove from the vehicle. Replacement of the seals is not as easy as removing the unit from the car, as the job requires special adjustments made to the unit and a very clean working area. Before you do this job please make sure that the leakage is from the rack and pinion and not on one of the hoses....
Regards Johngee10

YOU HAVE TO SAFELY RAISE SUPPORT VECHICLE ON JACK STANDS.MAKE SURE YOU HAVE VECHICLE PARKED ON LEVEL SOLID GROUND.ONCE VECHICLE RAISED.REMOVE FRONT WHEELS.REMOVE TIE RODS END COTTER PINS AND CASTLE NUTS.REMOVE TIE ROD ENDS FROM THE KNUCKLES.REMOVE FRONT STABILIZER BAR.POSITION THE DASH OPENING WEATHER SEAL FOR THE STEERING COLUMN OUT OF THE WAY.REMOVE OR DISCONNECT THE FOLLOWING.REMOVE PINCH BOLT RETAINING THE STEERING COLUMN INTERMEDIATE SHAFT COUPLING.REMOVE STEERING GEAR RETAINING NUTS BOLTS.REMOVE REAR SUBFRAME BOLTS.USE WIRE TO SUPPORT EXHAUST COMPONENTS UNLESS YOU ARE REMOVING THEM COMPLETELY.SUPPORT THE EXHAUST SYSTEM FLEX TUBE AND REMOVE THE FLEX TUBE TO DUAL CONVERTER Y PIPE ATTACHMENT.LOWER THE VECHICLE SLIGHTLY UNTIL THE REAR SUBFRAME SEPARATES FROM THE BODY APPROXIMATELY 4 INCHES.REMOVE THE HEAT SHIELD BAND AND FOLD THE HEAT SHIELD DOWN.ROTATE THE RACK AND PINION ASSEMBLY TO CLEAR THE BOLTS FROM THE FRONT SUBFRAME AND PULL TOWARD THE DRIVERS SIDE OF THE VECHICLE.PLACE A DRAIN PAN UNDER THE VECHICLE AND DISCONNECT THE POWER STEERING LINES.REMOVE THE RACK AND PINION ASSEMBLY THROUGH THE DRIVERS SIDE OF THE VECHICLE***** TO INSTALL ****** INSTALL NEW TEFLON O - RINGS ON THE POWER STEERING LINE FITTINGS. PLACE THE RACK AND PINION RETAINING BOLTS IN THE GEAR HOUSING.INSTALL RACK AND PINION ASSEMBLY THROUGH THE DRIVERS SIDE OF THE VECHICLE.INSTALL POWER STEERING LINES ON THE RACK AND PINION ASSEMBLY. INSTALL RACK AND PINION ASSEMBLY ON THE SUBFRAME.INSTALL ******** HEAT SHIELD.INSTALL TIE ROD ENDS TO THE KNUCKLES TIGHTEN THE CASTLE NUTS AND INSTALL THE COTTER PINS.INSTALL STABILIZER BAR.INSTALL RACK AND PINION ASSEMBLY RETAINING BOLTS.TORQUE THEM TO 85 - 99 FT LBS. RAISE VECHICLE UNTIL SUBFRAME CONTACTS THE BODY.INSTALL REAR SUBFRAME RETAINING BOLTS TORQUE THEM TO 83 - 112 FT LBS.INSTALL EXHAUST SYSTEM FLEX TUBE TO DUAL CONVERTER Y PIPE.INSTALL FRONT WHEELS.INSTALL A NEW PINCH BOLT IN THE STEERING COLUMN INTERMEDIATE SHAFT COUPLING ON THE RACK INPUT SHAFT TORQUE PINCH BOLT TO 25 - 33 FT LBS.POSITION THE STEERING COLUMN OPENING WEATHER SEAL OVER THE STEERING GEAR HOUSING.LOWER THE VECHICLE FILL THE POWER STEERING FLUID RESERVOIR. START THE VECHICLE AND CHECK FOR LEAKS. CHECK FOR PROPER WHEEL ALIGNMENT AND STEERING WHEEL POSITION.BLEED POWER STEERING SYSTEM.

there is a pinch bolt that holds it in, make sure you straighten the steering wheel first and lock it down with something so it cant move, then remove the pinch bolt and the pressure and discharge lines from the rack there are return lines within the rack that go side to side, you dont need to remove those. Make sure the replacement rack is even when putting back into steering yolk

Section 11-02C: Steering Gear, Power Rack and Pinion, Explorer 1996 Explorer with Power Rack and Pinion Steering Workshop Manual REMOVAL AND INSTALLATION Steering Gear SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Pitman Arm Puller T64P-3590-F
Removal

1. Start engine.
   

1. Rotate steering wheel from lock-to-lock (entire gear travel). Record n umber of rotations.
   

1. Divide the number of rotations by two. This gives the required number of turns to place system in the on-center position.
   

1. NOTE: Verify the front wheels and steering wheel are in the straight-ahead position.
   
   From the lock position, rotate steering wheel the number of turns determined in Step 3. This places the gear in the on-center position.
   
   
   Steering Gear, Explorer
   
   
   
   
   

1. NOTE: Do not rotate steering column when intermediate shaft is disconnected or DAMAGE TO CLOCKSPRING will result.
   
   Remove bolt retaining the lower steering column shaft to the steering gear input shaft.
   
   
   
   
   

1. Disconnect the lower steering column shaft from the steering gear.
   

1. Remove stabilizer bar attachment from frame for clearance to remove gear.
   

1. Unscrew the quick connect fittings for the power steering pressure hose (3A719) and power steering return hoses (3A713) at the steering gear housing (3548).
   
   
   Power Steering Hose Connections
   
   
   
   
   
   Item Part Number Description 1 3A674 Power Steering Pump 2 3A719 Power Steering Pressure Hose 3 3F780 Power Steering Cooler and Hose Assembly 4 3504 Steering Gear 5 5005 Frame

1. Plug ends of fluid lines removed and ports in gear to prevent damage and entry of dirt.
   

1. Remove two (2) nuts from P/S cooler.
   

1. Remove P/S cooler from vehicle.
   

1. Remove and discard the cotter pin retaining the nut to tie rod end (3A130) and remove nut.
   

1. Separate tie rod ends from front wheel spindle (3105) using Pitman Arm Puller T64P-3590-F.
   
   
   
   
   

1. Remove the two nuts, bolts, and washer assemblies retaining steering gear (3504) to front crossmember (5019).
   

1. Remove steering gear from vehicle. If required, remove steering gear mounting bracket housing insulators (3F640) and steering gear insulators (3C716) from steering gear housing.
   
   
   
   
   
   Item Part Number Description 1 N807881-S60 Bolt 2 385935-S36 Washer 3 3F640 Steering Gear Mounting Housing Insulator 4 3504 Steering Gear 5 N800255-S60 Nut 6 5019 Front Crossmember 7 3C716 Steering Gear Insulator

Installation

1. If removed, install steering gear mounting insulators into the steering gear housing.
   

1. Push the steering gear mounting insulator and steering gear insulator in until there is no space between the lip on the insulator and steering gear housing.
   

1. Position steering gear on front crossmember. Install nuts, bolts and washers retaining steering gear to front crossmember. Tighten to 128-172 Nm (94-127 lb-ft).
   

1. Position power steering cooler onto bolts and install nuts. Tighten nuts to 68-92 Nm (50-68 lb-ft).
   

1. NOTE: The fittings design allows the power steering pressure hose and power steering return hose to swivel when properly tightened. Do not attempt to eliminate looseness by overtightening, since this can cause damage to fittings.
   
   Connect power steering pressure hose and power steering return hose to appropriate ports on steering gear housing. Tighten fittings to 27-34 Nm (20-25 lb-ft).
   

1. NOTE: Make sure the tie rod ends (3A131) are seated in the tapered spindle holes to prevent rotation while tightening nut.
   
   With the steering gear, steering wheel (3600) and wheel (1007) in the on-center position, attach the tie rod end to front wheel spindle and tighten to 56-76 Nm (77-103 lb-ft).
   

1. If necessary, advance tie rod nuts to the next slot. Install cotter pins.
   

1. NOTE: Verify that no rotation from the on-center position has occurred.
   
   Position steering column lower intermediate shaft over steering gear input shaft. Outer input shaft dust shield must be in place. Replace pinch bolt and tighten to 41-56 Nm (30-42 lb-ft).
   

1. Replace the front wheel and tire assemblies. Refer to Section 04-04 .
   

1. Replace wheel covers.
   

1. Lower vehicle.
   

1. Refill power steering oil reservoir (3A697) with Premium Power Steering Fluid E6AZ-19582-AA or equivalent meeting Ford specification ESW-M2C33-F.
   

1. Purge air from steering system. Refer to Section 11-00 . Verify absence of any unusual power steering noise.
   

1. Check and adjust toe alignment specifications. Refer to Section 04-00 .
   

1. Make sure steering gear operates correctly and is not leaking.
   

1. Check and adjust fluid level in power steering oil reservoir.
   

if fluid is flowing out the bellows, you need to replace the steering rack assembly. There is no fluid in the area of the inner tie rod. The seal is just before the tie rod.

Steering Gear
The power rack and pinion steering gear is serviced as a power steering short rack (3L547). The front wheel spindle tie rods (3280) and tie rod ends (3A130) are serviced individually. -------------------------------------------------------------------------------------------

• The power rack and pinion steering gear incorporates quick connect fittings for the power steering pressure hose (3A719) and power steering return hose (3A713) that allow the lines to swivel. This is normal and does not indicate loose fittings.
• If the fittings leak, check to make sure they are tightened to 14-20 Nm (10-14 lb-ft). Do not overtighten.
• If the leak is not corrected, replace the fitting seals.

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Section 11-02: Steering System, Power 1997 Windstar Workshop Manual
REMOVAL AND INSTALLATION Tie Rod End Steering Gear Installed
Removal

1. Remove and discard cotter pin and nut from worn tie rod end (3A130).
   

1. Disconnect tie rod end from front wheel knuckle (3K185), using Tie Rod End Remover TOOL-3290-D or equivalent.
   

1. Hold tie rod end with a wrench and loosen tie rod end jam nut.
   

1. Note depth to which tie rod end was located by using the jam nut as a marker. Grip tie rod end with a pair of suitable pliers and remove tie rod end from front wheel spindle tie rod (3280).
   

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11-02: Steering System, Power 1997 Windstar Workshop Manual
REMOVAL AND INSTALLATION Steering Gear Removal

1. Raise vehicle on a twin post hoist and remove wheel and tire assemblies. Refer to Section 00-02 .
   
   
   
   
   

1. Support vehicle with jackstands under front jack pads.
   

1. Remove tie-rod end cotter pins and nuts and remove tie rod ends (3A130) from front wheel knuckle (3K185). Refer to Section 04-01 .
   

1. Remove front stabilizer bar (5482). Refer to Section 04-01 .
   

1. Disconnect heated oxygen and catalyst monitor sensors.
   

1. Support flex pipe.
   

1. Remove bolts and disconnect flex pipe from the converter.
   

1. Raise dash opening steering column opening weather seal (3513) (secondary) above the steering gear housing (3548).
   

1. Remove pinch bolt retaining steering column intermediate shaft coupling (3A525) to power steering gear input shaft and control (3D517) and disconnect the shaft.
   

1. Remove nuts from steering gear-to-front subframe retaining bolts. Remove bolts.
   

1. Remove rear subframe-to-body retaining bolts.
   

1. Lower twin post hoist carefully until rear of subframe (5R003) separates from body, approximately four inches.
   

1. Remove heat shield band and fold shield down.
   

1. Rotate power rack and pinion steering gear to clear bolts from front subframe (5C145) and pull left to facilitate line fitting removal.
   

1. Place a drain pan under vehicle and remove line fittings.
   

1. Remove power rack and pinion steering gear through LH wheel well.
   

1. Remove and discard the O-rings.
   

Installation

1. Install new Teflon® O-rings on line fittings as outlined.
   

1. Place steering gear retaining bolts in steering gear housing.
   

1. Install power rack and pinion steering gear through LH wheel well.
   

1. Install power steering line fittings to power rack and pinion steering gear.
   

1. Position power rack and pinion steering gear into front subframe.
   

1. Install ******** heat shield.
   

1. Install tie-rod ends to front wheel knuckle. Install nuts and new cotter pins. Refer to Section 04-01 .
   

1. Install LH front stabilizer bar. Refer to Section 04-01 .
   

1. Install steering gear to subframe mounting nuts. Tighten to 115-135 Nm (85-99 lb-ft).
   

1. Raise hoist until rear subframe contacts body.
   

1. Install rear subframe to body retaining bolts. Tighten to 113-153 Nm (83-112 lb-ft).
   

1. Install exhaust system flex tube to dual converter Y pipe (5F250) and remove flex tube support.
   

1. Connect heated oxygen and catalyst monitor sensors.
   

1. Install tire and wheel assemblies. Tighten lug nuts (1012) to 115-142 Nm (85-104 lb-ft).
   

1. Using a new pinch bolt, install the steering column intermediate shaft coupling on the power steering gear input shaft and control and the lower steering column shaft. Tighten the pinch bolt to 34-46 Nm (25-33 lb-ft).
   

1. Position steering column opening weather seal (secondary) over the steering gear housing. Tighten nuts to 4.5-6.3 Nm (40-55 lb-in).
   

1. Remove jackstands and lower vehicle.
   

1. Fill power steering oil reservoir (3A697) with Premium Power Steering Fluid E6AZ-19582-AA or equivalent meeting Ford specification ESW-M2C33-F. Refer to Section 11-00 .
   

1. Check system for leaks and proper operation.