Rack and Pinion Replacement 98 Windstar

I was wondering if anyone has replaced the rack and pinion on a Windstar? If so how difficult is it? We had it replaced about 4 years ago but the garage we took it to put on a used one from a junkyard and the seal is leaking. So now it needs a new one I'm wanting to try to tackle this myself since I am pretty good with cars. Any advice or help would be appreciated.

A good repair manual would be very helpful.
You can get FREE repair information on AutoZone's website that is really good.

Use Mercon or Mercon V ATF for power steering fluid when you add.
I would replace all the fluid and even maybe add a magnefine filter, like I have in my pictures (available at www.rockauto.com ) to catch any particles that may still be loose in the fluid system.

I have never replaced a steering rack myself, so I have no pictures of that process or any other help to offer.

I've replaced the steering rack, engine and transmission on my '98 (all on separate occassions) so I can maybe help.

I don't know how detailed information you need, but briefly...you'll need to lower the subframe that the engine and tranny are attached to. It's really not that difficult, though, so don't be scared about that part.


Here's what I did (I may miss a couple details, but this is pretty high level):

-Jack the van up as high as you can and put on jack stands.
-Remove both front wheels.
-Disconnect the tie rod ends from the suspension on both sides.
-Disconnect the sway bar end links from the suspension on both sides.
-Loosen the two front subframe bolts so you have about 1/2 inch of drop in the subframe.
-Now you'll need to remove both rear subframe bolts and you'll need to figure out a way to support the whole subframe with a jack of some sort.
-You'll need to lower the rear of that subframe enough to be able to remove the 2 bolts on each side (13mm I believe) that hold the sway bar to the subframe.
-Once the sway bar is out of the way, now you can attack the steering rack. (the 2 nuts that hold the steering rack in are right above the sway bar)
-Remove both power steering lines that attach to the steering rack (18mm-open ended wrench will be most beneficial). If I remember correctly, these are reverse threaded. Also, REMEMBER which one goes to which hole. It's not pretty if you hook them up to the wrong one (don't ask :banghead:)
-Remove the 2 large nuts that hold the steering rack to the subframe (24mm maybe?)
-Slide the steering rack out one of the two sides.
-Installation is the reverse

Before you reattach the 2 power steering lines to the rack you'll need to remove the remnants of 2 teflon o-rings and purchase 2 new ones from Ford. They are about $1.00 each. Buy a few extra in case you mess one of them up. They are NOT reusable.

I can't remember if I needed to detach the exhaust from the manifolds, but I think it can be done without doing that.

Let me know if I can answer any more questions.

Dale

Edit: Oh, one more thing. Hooking up the PS lines to the rack is a major PITA. You don't have much room to work and they are stiff and you have to get them to line up just perfectly before the threads will grab.

Ok now we have the rack and pinion changed but the steering is so tight and feels like something is sticking when you drive down the road and make a right turn. What could the problem be now??? :banghead: Or is a new rack supposed to feel so tight?

I don't know that I can help with that. The one that I replaced on mine was a junkyard rack. I've never put on a new one. I wouldn't think it should feel tight at all, though.

Are you sure it's full of fluid? And you used the correct fluid? Is the pump whining a lot or is it quiet?

Dale