Rack and Pinion Boots

Replace worn or torn rack and pinion boots on the recirculating ball steering system of a 1972 Ford F-100, preventing contamination and steering component damage.

Warnings

Tools required

Parts

• Steering gear sector shaft seal/boot kit × 1 — Use OEM specification
• Tie rod end dust boots (if applicable) × 2 — Use OEM specification
• Boot clamps (typically included in kit) × 4 — Stainless steel worm gear or crimp type

Fluids

• Type F ATF (power steering) — 1 qt

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks behind rear wheels
3. Turn steering wheel to center position and lock ignition
4. Raise front of vehicle with floor jack and support securely on jack stands at frame rails
5. Remove front wheels for better access to steering linkage

Procedure

1. 1

   Locate and inspect steering box sector shaft
   From underneath the vehicle, locate the steering box mounted on the driver side frame rail. Identify the sector shaft where it exits the bottom of the steering box and connects to the Pitman arm. Inspect the rubber boot/seal around the sector shaft for cracks, tears, or grease leakage. This is the primary 'boot' on this steering system.
2. 2

   Mark Pitman arm orientation
   Using a paint pen or scribe, mark the orientation of the Pitman arm relative to the sector shaft splines. This ensures proper alignment during reassembly and maintains steering wheel center position. Note the relationship between the arm and shaft.
3. 3

   Remove Pitman arm retaining nut
   Remove the castle nut securing the Pitman arm to the sector shaft. Remove the cotter pin first if present. The nut size is typically 1-1/8 inch. Keep track of any washers under the nut.
4. 4

   Separate Pitman arm from sector shaft
   Install a Pitman arm puller onto the arm. Tighten the puller slowly and evenly until the arm releases from the tapered sector shaft. Do not strike the arm or shaft with a hammer as this can damage the steering box. Place drain pan underneath as power steering fluid will drain from the sector shaft opening.
5. 5

   Remove old sector shaft boot
   With the Pitman arm removed, cut or release the boot clamps securing the sector shaft boot. Use boot clamp pliers or carefully cut the clamps with side cutters. Slide the old boot off the sector shaft and steering box housing. Note the orientation and seating position for installation.
6. 6

   Clean sector shaft and housing
   Clean the sector shaft splines and the boot seating area on the steering box housing using a wire brush and shop rags. Remove all old grease, dirt, and debris. Inspect the sector shaft seal inside the housing for damage. If the internal seal is leaking severely, the steering box may require rebuild or replacement.
7. 7

   Install new sector shaft boot
   Slide the new sector shaft boot over the sector shaft from the bottom. Position the boot so it seats properly in the groove on the steering box housing and covers the sector shaft adequately. Ensure the boot is not twisted and sits evenly around the circumference.
8. 8

   Secure boot with clamps
   Install new boot clamps at both ends of the boot. Position one clamp securing the boot to the steering box housing and one securing the boot to the sector shaft. Tighten clamps evenly using boot clamp pliers or appropriate tool. Ensure boot is not kinked or pinched by the clamps.
9. 9

   Inspect tie rod end boots
   While the steering linkage is accessible, inspect the rubber dust boots on both inner tie rod ends (at the center link) and outer tie rod ends (at the steering knuckles). If any boots are torn, cracked, or missing, they should be replaced by separating the tie rod ends and sliding new boots into place with appropriate clamps.
10. 10

    Reinstall Pitman arm
    Clean the sector shaft taper and Pitman arm taper bore. Align the marks made during disassembly and slide the Pitman arm onto the sector shaft. The arm should slide on easily by hand to the first taper contact. Install the washer and castle nut.
11. 11

    Torque Pitman arm nut
    Torque the Pitman arm retaining nut to specification. While no torque spec is provided in the database, typical specification for this application is 170-180 ft-lbs. Tighten to proper specification and install new cotter pin through castle nut and shaft. Bend cotter pin ends to secure.
12. 12

    Refill power steering system
    Add Type F ATF to the power steering reservoir to the proper level. Start engine and turn steering wheel slowly from lock to lock several times to purge air from the system. Check fluid level and add as needed. Inspect for leaks around the new sector shaft boot.

Reassembly

1. Reinstall front wheels and torque lug nuts to specification
2. Lower vehicle from jack stands
3. Perform final steering system inspection with vehicle weight on suspension
4. Top off power steering fluid if needed after test driving

Verification

• Check that sector shaft boot is properly seated and clamps are secure with no leaks
• Verify steering wheel returns to center position correctly
• Test drive vehicle and confirm no unusual steering noises or binding
• Recheck power steering fluid level after test drive
• Inspect all steering boots for proper installation and no damage
• Verify no power steering fluid leaks from steering box or connections

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