DIY Network

Ford Ranger Pick-Up: Rack-and-Pinion Steering Replacement Bruce Bonebrake addresses steering problems on a 1998 Ford Ranger pick-up. From "Weekend Mechanic" episode WKM-411

In this project, Weekend Mechanic host Bruce Bonebrake solves steering problems on a 1998 Ford Ranger pick-up by replacing a worn rack-and-pinion system. After an evaluation, Bruce removes the old rack unit, replaces it with a complete new system including new tie rod ends and bleeds the steering system. A test drive confirms the successful repair.

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	Bruce compares the components of new and conventional steering systems.
	The replacement rack-and-pinion steering system (upper) and a conventional steering system (lower).

Project Overview

When it comes to the steering system in your vehicle, you may have a problem and not even know it. It's normal for steering parts to wear out over tine, but it might happen so gradually that you won't really notice a change until it gets to be severe. On our project vehicle, we've begun to notice a tendency to "stick and release" when turning.

For our project, Bruce Bonebrake inspects and tests the steering system on the truck to isolate the problem and determines that the entire rack will need to be replaced. He removes the stock rack-and-pinion assembly and the power-steering fluid cooler. Next, he assembles the new steering rack and installs it along with the power-steering fluid lines and fluid cooler. Finally he adds power steering fluid, bleeds the system and takes the truck for a test drive to check the results of the repair.

DIY Difficulty Rating for the Project: We gave this project a difficulty rating of 2 on a 5-point intermediate-level scale. Allow yourself about five hours if you're replacing the entire steering rack.

Important: Included here is a basic summary of the steps in this automotive procedure as shown in the episode. These steps are general guidelines that are applicable to most vehicles. With any particular vehicle, there may be procedures, specifications, settings, tolerances, components, etc. that are specific to that vehicle. There are also variations according to the type and brand of repair-kit or replacement parts you select. Always consult your vehicle's service manual when undertaking significant automotive repairs, and read and follow the manufacturer's directions and precautions that come with your kit or replacement parts.

The tie-rod end

Tools and materials:

In addition to standard auto-mechanic's tools (wrenches, ratchets, extenders, screwdrivers, nut-drivers, torque wrench, etc.), some of the tools required for this project include

tape measure
tie rod separator
penetrating oil
power steering fluid
vehicle service manual (torque specifications)

Safety Alert: As a standard safety precaution, don't rely solely on a jack to support the weight of a vehicle. When using a jack to access or work beneath a vehicle, always use jack stands for support. Make sure that the jack and stands that you use are rated for the weight and type of your vehicle.

Safety Alert: Always wear eye protection and ear protection, and follow proper safety precautions, when working with power tools. Also wear eye protection any time that you are working beneath a vehicle or around toxic or caustic fluids.

Safety Alert: Always dispose of automotive fluids (antifreeze, motor oil, transmission fluid, power steering fluid, etc.) and other toxic substances responsibly. Most auto center offer recycling of automotive fluids.

Figure A

Diagnosis and Steering System Assessment

• Check the steering and suspension systems on your vehicle to determine which system is creating the problem. You should check the power-steering fluid level and inspect the belt.

• Remove the power-steering cap (figure A) and check the level of the power steering fluid. Our Ranger has a dipstick that has a "hot" and "cold" level mark on it. Our fluid level appears okay.

• Check the belt for deflection as well as wear-and-tear. In our case, the belt is in great condition.

• Since there is no problem with the power steering fluid or belt, the next step is to raise the car on jack stands to inspect underneath the car.

  Safety Alert: When raising a vehicle, make sure it is on level ground and the parking brake is on. It's also a good idea to place a piece of wood on the end of the jack pad so you will have full contact with the frame.
  

  Bruce dismantles the old steering system.

• You'll need to determine if the problem is with steering or suspension. To determine whether it is the rack-and-pinion or the suspension, disconnect the outer tie rod ends from both wheels on the rack-and-pinion, and then turn the wheels to see if the problem is still there. If it is, that means the rack is bad.

• Weekend Mechanic Pro Tip: When working on old rod fasteners such as tie rod end bolts, it 's a good idea to spray them with penetrating oil to loosen them and avoid damaging the bolts.

• Remove the cotter pin, then the castle nut.

• To pry the tie rod end off, use a tie rod separator.

• Use a mallet to force the tie rod separator into the joint and pry the bolt end out. Do the same on the other side to free up the driver’s side tie rod end.

• With the tie rod ends removed, test the steering. If the rack appears to be sticking, jerking or not operation smoothly, then the problem is in the rack.

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