Power Steering Gear Box

This procedure covers the removal and replacement of the power steering gear box on a 1972 Ford F-100 with 302ci V8, including disconnecting steering linkage, fluid lines, and mounting bolts.

Warnings

Tools required

Parts

• Power steering gear box × 1 — Use OEM specification or quality remanufactured unit
• Power steering gear box mounting gasket/seal × 1 — Frame mounting seal
• Pitman arm nut × 1 — Replace if damaged
• Power steering fluid hose washers × 4 — Pressure and return line copper washers

Fluids

• Type F ATF — 2 qt

Preparation

1. Park vehicle on level surface and set parking brake firmly
2. Chock rear wheels securely
3. Raise front of vehicle and support on jack stands at frame rails behind front crossmember
4. Remove front wheels for better access (optional but recommended)
5. Turn steering wheel to center position and lock steering column or mark wheel position with tape
6. Pump out power steering fluid reservoir using turkey baster or fluid pump into drain pan
7. Place large drain pan under steering gear box area

Procedure

1. 1

   Disconnect power steering hoses
   Locate the pressure and return lines at the steering gear box on the driver side frame rail. Use a flare nut wrench to loosen the pressure line fitting (typically 5/8") at the gear box inlet. Allow fluid to drain into pan. Remove the return line fitting. Cap or plug the hose ends and gear box ports with clean rags to prevent contamination. Verified detail (On this Ford integral gear box the pressure and return ports are identified by fitting size and location, not reliably by which is 'higher.' This orientation cue is unverified and could mislead reassembly.): Identify the pressure line versus return line by fitting size and port markings, not merely by position, and note the routing before disconnecting.
   ℹ️Note the orientation and routing of hoses for reinstallation. The pressure line typically has a higher fitting.
2. 2

   Mark pitman arm position
   Locate the pitman arm where it connects to the steering gear sector shaft. The sector shaft will have a master spline (larger or keyed position). Use a paint marker or scribe to mark the exact relationship between the pitman arm and the sector shaft. This ensures proper steering wheel centering on reassembly.
   ⚠Failure to mark this relationship will result in an off-center steering wheel requiring front end realignment.
3. 3

   Disconnect pitman arm from center link
   Locate where the pitman arm ball stud connects to the center link (drag link). Remove the cotter pin and castle nut from the ball stud. Use a pitman arm puller or pickle fork to separate the tapered ball stud from the center link. If using a pickle fork, note that it may damage the ball joint boot.
   ℹ️Apply penetrating oil to the taper 15 minutes before separating if joints appear rusty or seized.
4. 4

   Remove pitman arm from sector shaft
   Remove the pitman arm retaining nut from the sector shaft using a large socket (typically 1-1/8" or 1-1/4"). Install a pitman arm puller with the jaws gripping the pitman arm and the forcing screw centered on the sector shaft. Tighten the puller forcing screw while striking the tool body with a hammer to shock the taper loose. Remove the pitman arm once separated.
   ⚠Do not attempt to pry or hammer the pitman arm off without a proper puller. This will damage the arm, sector shaft, or gear box.
5. 5

   Remove steering gear mounting bolts
   Locate the mounting bolts securing the steering gear box to the driver side frame rail (typically 2 bolts on this application). These bolts pass through the gear box mounting flange into the frame. Remove all mounting bolts using a socket and extension. Support the gear box by hand as the last bolt is removed. Verified detail (The number of gear box-to-frame mounting bolts on the 1972 F-100 is unverified; these boxes are commonly retained by 3 bolts but this should be confirmed for the specific chassis before ordering hardware.): Locate the mounting bolts (typically 3) securing the steering gear box to the driver side frame rail; verify the exact count on your vehicle.
   ℹ️The gear box weighs approximately 15-20 pounds and may be awkward to handle in tight quarters.
6. 6

   Remove steering gear box
   Carefully maneuver the steering gear box out from between the frame rail and engine. The gear box will need to be rotated and angled to clear the frame and steering shaft coupling. The input shaft (worm shaft) will slide out of the flexible coupling at the steering column. Once clear, lower the gear box and remove from vehicle.
   ℹ️Watch the input shaft splines to avoid damaging the flexible coupling during removal.
7. 7

   Inspect and clean mounting surfaces
   Clean the frame rail mounting surface with a wire brush, removing old gasket material, rust, and debris. Inspect the frame mounting area for cracks or damage. Check the flexible coupling at the steering column for wear, cracks, or looseness. Clean the sector shaft splines if reinstalling the original pitman arm.
   ⚠If the flexible coupling shows wear or excessive play, it must be replaced before installing the new gear box.
8. 8

   Prepare new steering gear box
   Remove shipping plugs or caps from the new gear box ports. Install new copper sealing washers on the pressure and return line fittings if provided with the gear box. Verify the gear box sector shaft is in the center position by rotating the input shaft fully in one direction, counting the turns, then rotating back half that number of turns to center. Ensure the input shaft and flexible coupling clamp surfaces are clean and dry; do not lubricate the coupling interface.
   ℹ️Most remanufactured gear boxes are shipped in the center position. Verify before installation.
9. 9

   Install new steering gear box
   Position the new frame mounting gasket/seal on the gear box mounting flange. Carefully maneuver the gear box into position between the frame rail and engine, aligning the input shaft with the flexible coupling. Rotate and angle as needed to clear obstructions. Slide the input shaft splines into the flexible coupling while aligning the mounting flange with the frame rail holes.
   ⚠Ensure the flexible coupling is fully engaged on the input shaft splines before installing mounting bolts.
10. 10

    Install steering gear mounting bolts
    Install all mounting bolts through the gear box flange into the frame rail. Start all bolts by hand before tightening any. Tighten the mounting bolts evenly to seat the gear box. Final torque specification must be verified against the 1972 Ford truck shop manual before final tightening.
11. 11

    Install pitman arm
    Align the pitman arm with the sector shaft using the alignment marks made during disassembly. The master spline will only allow installation in the correct position. Slide the pitman arm fully onto the sector shaft taper. Install the pitman arm retaining nut and tighten to the factory specification (verify exact torque in the 1972 Ford truck shop manual before final tightening). Stake the nut or use thread locking compound per factory specification.
    ℹ️The pitman arm must be fully seated on the taper before tightening the nut. Verify no gap exists between arm and sector shaft.
12. 12

    Connect pitman arm to center link
    Position the pitman arm ball stud into the center link taper. Install the castle nut and tighten to specification (typically 50-60 ft-lbs). Align the castle nut slots with the cotter pin hole and install a new cotter pin. Bend the cotter pin ends to secure.
13. 13

    Connect power steering hoses
    Remove the protective caps from the gear box ports and hose ends. Install new copper sealing washers on both the pressure and return line fittings. Connect the pressure line (higher pressure fitting, typically on top) to the gear box inlet port. Connect the return line to the return port. Tighten both fittings using a flare nut wrench to the manufacturer-specified torque (verify pressure and return fitting torque separately in the shop manual). Do not overtighten or the fittings may strip. Verified detail (Exact torque specification for power steering line fittings on 1972 Ford F-100 steering gear box): 15.0 lb-ft (20.0 Nm)
    ⚠Cross-threading hydraulic fittings will result in leaks and possible gear box damage. Start threads carefully by hand.
14. 14

    Fill power steering system
    Remove the power steering reservoir cap. Fill the reservoir with Type F ATF to the COLD or MIN mark. Start the engine and allow it to idle. Turn the steering wheel slowly from lock to lock 10-15 times to bleed air from the system. Check the fluid level and add as needed. Continue running and cycling the steering until no air bubbles appear in the reservoir and fluid level stabilizes. Top off to the proper level.
    ℹ️Air in the system will cause noise, poor steering assist, and possible gear box damage if not properly bled.
    ⚠Do not hold the steering wheel at full lock for more than 3-5 seconds as this creates excessive pressure and heat.
15. 15

    Check for leaks and verify operation
    With the engine running, inspect all connections at the gear box, hose fittings, and reservoir for leaks. Wipe connections dry and observe for fresh fluid seepage. Turn the steering wheel through full travel in both directions and verify smooth operation with no binding, noise, or excessive effort. Check the steering wheel center position with wheels pointed straight ahead.
    ℹ️Minor weeping at fittings may seal after initial heat cycling. Retorque fittings if seepage persists.

Reassembly

1. Reinstall front wheels if removed and torque lug nuts to specification (typically 100 ft-lbs for 1972 F-100)
2. Lower vehicle from jack stands
3. Recheck power steering fluid level after the system reaches operating temperature
4. Test drive vehicle at low speed in a safe area to verify steering response and center position
5. Recheck all connections for leaks after test drive
6. If steering wheel is not centered with wheels straight, alignment marks may have been misaligned or a front end alignment may be required

Verification

• Engine runs smoothly with power steering pump operating quietly (no whining, groaning, or cavitation noises)
• Steering wheel turns smoothly with light effort in both directions
• No fluid leaks visible at gear box mounting area, hose connections, or reservoir
• Steering wheel is centered when front wheels are pointed straight ahead (minor adjustment acceptable)
• Power steering fluid level is at proper mark on reservoir with engine at operating temperature
• No excessive play in steering wheel (1-2 inches of play at rim is normal for 1972 F-100)
• Vehicle tracks straight during test drive with hands lightly on wheel

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