Attachment III - Technical Information

OVERVIEW

This program involves checking and adjusting the torque on the steering gear yoke plug lock ring.

INSPECTION

1. If equipped, turn off the air suspension switch, then raise the vehicle on a hoist.

2. Disengage the power steering line clip to gain access to the steering gear yoke plug and lock ring.





3. Inspect the steering gear yoke plug lock ring. See Figure 1.

^ If the lock ring is MISSING - call the Special Service Support Center at 1-800-325-5621 for approval to replace the rack and pinion assembly. Refer to Sections 211-02 and 204-00 of the 2004 Crown Victoria/Grand Marquis/Marauder or Town Car Workshop Manual for steering gear replacement and wheel alignment procedures.

^ If the lock ring is present - go to the Service Procedure.

SERVICE PROCEDURE

1. Check to see if the yoke plug rotates/moves to determine if the lock ring is loose. (If the lock ring is loose, the yoke plug may have moved out of adjustment).

A) Set torque wrench to 10 Nm (86 lb-in).

B) Using a 3/4-in socket, check to see if the yoke plug moves with less than 10 Nm of torque.

CAUTION:
DO NOT EXCEED 10 Nm WHEN PERFORMING THIS CHECK.

^ If the yoke plug moves/rotates at a torque less than 10 Nm, the yoke plug needs to be adjusted. Proceed to Step 2.

^ If the yoke plug does not move with up to 10 Nm of torque, the yoke plug DOES NOT need to be adjusted. Proceed to Step 3.

2. If lock ring is loose, adjust the yoke plug as follows:

a) Loosen the lock ring

b) Using a 3/4-inch socket, turn the yoke plug clockwise all the way into the steering gear housing until the yoke plug bottoms.

c) Tighten the yoke plug 6 Nm (53 lb-in).





d) Turn the yoke plug 45 degrees (1/8 of turn) counterclockwise. See Figure 2.

3. CAUTION: The use of a crowfoot adapter on a torque wrench increases the length of the tool and changes the actual torque value. To achieve the proper torque on the fastener, you must use the formula shown in Figure 3 to calculate the proper setting for the torque wrench/crowfoot you are using. See Figure 3.








Use a 3/4-inch socket to hold the yolk plug in position. Use a torque wrench with Pinion Housing Yoke Locknut Wrench 178P-3504-H or a 1-7/8-inch crow foot adapter to tighten the lock ring to 45 Nm (33 lb-ft). See Figures 3 and 4.

4. Secure the power steering line clip.

5. Lower the hoist and, if equipped, turn the air suspension switch ON.