Mercury F7AZ-3504-FDRM Gear Assembly - Steering

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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.

The rack and pinion removal process for 2002 and earlier models includes several steps. First, remove stone shields by unclipping the lock tab. Disconnect pressure and return lines, fluid line fittings, and pinch bolt on the flex coupling clamp. The Pitman arm should be detached from the sector shaft that supports the rack and pinion after removing it with attachment bolts. While installing, align the flex coupling on the steering shaft assembly so that its wheel spokes are horizontal. The rack and pinion mounting bolts should be installed and tightened. Return the Pitman arm back onto the sector shaft and secure the Pitman arm nut. Flex coupling to the rack and pinion input shaft clamp bolt shall be installed and tightened. Reconnect pressure and return lines securely. Fill the power steering system and bleed it out. For 2003 and later models, however, things are done slightly differently. Park with wheels straight ahead then loosen the front wheel lug nuts using a small wrench while raising the vehicle with jack stands with the parking brake applied. Place a drain pan under the rack and pinion unscrew the power steering pressure and return lines using a flare-nut wrench.

The rack and pinion removal process for 2002 and earlier models includes several steps. First, remove stone shields by unclipping the lock tab. Disconnect pressure and return lines, fluid line fittings, and pinch bolt on the flex coupling clamp. The Pitman arm should be detached from the sector shaft that supports the rack and pinion after removing it with attachment bolts. While installing, align the flex coupling on the steering shaft assembly so that its wheel spokes are horizontal. The rack and pinion mounting bolts should be installed and tightened. Return the Pitman arm back onto the sector shaft and secure the Pitman arm nut. Flex coupling to the rack and pinion input shaft clamp bolt shall be installed and tightened. Reconnect pressure and return lines securely. Fill the power steering system and bleed it out. For 2003 and later models, however, things are done slightly differently. Park with wheels straight ahead then loosen the front wheel lug nuts using a small wrench while raising the vehicle with jack stands with the parking brake applied. Place a drain pan under the rack and pinion unscrew the power steering pressure and return lines using a flare-nut wrench.