Here's a general outline. Specific steps and tools may vary slightly depending on your van's exact configuration:
1. Safety First:
* Disconnect the battery: This prevents accidental short circuits.
* Engage the parking brake: Firmly secure the van.
* Use jack stands: Never work under a vehicle supported only by a jack.
* Wear safety glasses and gloves: Protect yourself from injury.
2. Preparation:
* Gather tools: You'll need a variety of tools, including wrenches (various sizes, including metric and standard), sockets, a pickle fork (or similar steering wheel puller), a large capacity torque wrench, a floor jack, jack stands, a drain pan, possibly a steering wheel puller, and potentially a steering alignment tool.
* Consult a repair manual: A factory service manual specific to your 1992 E-150 is invaluable. It will provide precise torque specifications, diagrams, and detailed procedures.
3. Removal of the Old Steering Box:
* Drain the power steering fluid: Locate the power steering fluid reservoir and drain the fluid into a suitable container.
* Disconnect the steering linkage: This involves disconnecting the drag link and the tie rods from the steering box. Mark their positions before disconnecting to aid in reinstallation and alignment.
* Disconnect the power steering hoses: Carefully disconnect the high-pressure and low-pressure hoses from the steering box. Be prepared for some fluid leakage. Have rags ready.
* Disconnect the steering shaft: This may require specialized tools depending on the specific design. You may need to separate the steering column from the steering box.
* Remove the steering box mounting bolts: These bolts will likely be difficult to access, requiring extensions, wobbly sockets, or other specialized tools.
* Remove the steering box: Carefully lower the steering box out from its mounting location.
4. Installation of the New Steering Box:
* Position the new steering box: Carefully align the new steering box in its mounting location.
* Install the mounting bolts: Tighten the mounting bolts to the manufacturer's specifications (found in your repair manual).
* Reconnect the steering shaft: Ensure proper alignment and secure connection.
* Reconnect the power steering hoses: Double-check for proper connections to avoid leaks.
* Reconnect the steering linkage: Use your markings to ensure proper alignment. This is crucial for safe and correct steering.
* Fill the power steering fluid reservoir: Fill to the recommended level, using the correct type of fluid.
* Bleed the power steering system: This is necessary to remove air bubbles from the system. Refer to your repair manual for the bleeding procedure.
5. Post-Installation:
* Check for leaks: Inspect all connections for any fluid leaks.
* Test the steering: Carefully test the steering to ensure smooth and responsive operation.
* Have a wheel alignment performed: This is absolutely crucial. After replacing the steering box, a proper wheel alignment is essential for safe driving. A misaligned vehicle can lead to premature tire wear and unsafe handling.
Important Considerations:
* Power Steering Fluid: Use the correct type of power steering fluid recommended for your vehicle. Using the wrong fluid can damage the system.
* Torque Specifications: Always adhere to the manufacturer's torque specifications for all bolts and connections. Over-tightening can damage components, while under-tightening can lead to leaks or loosening.
Again, this is a complex job. If you lack experience with automotive repair, particularly steering system work, hire a qualified mechanic. A mistake could result in serious injury or damage. The cost of professional installation is far less than the potential cost of an accident caused by an improperly installed steering box.
