Ford Truck Rack Actuator Replacement Instructions

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The vehicle used in this example is a 1991 Ford Pickup truck. This section will detail the disassembly and re-assembly of the upper housing on an older style Ford tilt steering column. This design was used on most Ford trucks through 1991. The instructions will explain how to replace the ignition rack actuator.

DISASSEMBLY

1) Set the wheels in the straight-ahead position before beginning.


Then disconnect the battery.

2) Remove the horn pad for access to the steering wheel. Unscrew the 2 screws behind the wheel securing the horn pad.

3) Remove the steering wheel using a suitable puller if needed.

This will reveal the turn signal switch and inner components which need to be removed.





4) Remove the turn signal lever. This simply unthreads from the switch

5) Remove the ignition lock cylinder. To accomplish this, turn the lock to the “on” position. Under the column housing where the lock cylinder is, is an access hole. Depress the pin inside this hole and slide the lock cylinder out.

6) Remove the lock.







7) Carefully remove the 2 silver phillips head screws that secure the turn signal switch to the housing. Be careful not to damage the cancel tabs on the switch.

Remove the 1/4 head hex head for the key warning buzzer contact.






8) Pull and fold away the turn signal switch so it is out of the way. You may need to release the wire harness from underneath the column to allow enough access.








9) Remove the 3 black phillips head screws securing the housing to the column










10) Remove the housing by simply pulling it off the column. As noted in the next picture, a part may fall out. Do not lose this part.

This part, is part of the actuator mechanism that engages the ignition switch when you turn the key.

11) Remove the upper tilt housing spring using a large flat bladed screwdriver to collapse and pry it out of the way. This is not a heavy spring.










12) Remove the two tilt pivot pins using a 'pivot pin puller'. We sell this tool here if you do not have one.










13) Remove the snap ring securing the tilt housing to the shaft.











14) Releasing the tilt teeth on the bottom of the housing, remove the tilt housing. As shown in the next photo, this will reveal the broken actuator.








15) This part of the actuator is what guides the rod to engage the switch. When it breaks, there is no longer any support for the rod to move in the proper direction.












16) Remove the roll pin securing the rod to the actuator. DO NOT LOSE THIS SMALL PIECE















17) Remove the broken piece of the actuator by using a small right angle pick to slide it up and out of the tube. (Note: there may be a key release button on the bottom of the column or you may need to move the shift selector to allow the broken piece to release)





We sell this part here

RE-ASSEMBLY

Make sure the new actuator slides smoothly in the track before assembling. Some castings need to be filed to allow free movement.





1) Insert the rod into the actuator and squeeze the roll pin into place.

2) Holding the tilt teeth out of the way, slide the tilt housing back into place.

3) Insert the pivot pins on both sides and tap them into place with a small hammer.











4) Install the tilt spring into the housing using a flat bladed screwdriver.

5) Install the snap ring on the shaft securing the housing. Make sure the shaft is fully extended and the snap ring actually locks into the groove on the shaft. You may need to help the shaft ‘up’ to seat the lower bearing.







6) Using a long snap ring pliers, remove the snap ring, retainer and gear from the lock housing.








7) Insert the actuator gear mechanism that fell out before onto the pin of the new rack actuator.














8) Slide the lock housing onto the column over the turn signal switch. Make sure the rack actuator gear slides into the proper position and the steering wheel locking pin is exposed.







9) Secure the housing to the column with the 3 black phillips screws.

10) Reinstall the turn signal switch. Once again, you may need to pull the wires from the bottom of the column to allow the switch to fully seat.






11) Secure the switch and key buzzer contact using the 2 silver phillips screws and 1 black hex head screw. Do not damage the plastic cancel tabs!!

Aligning the Ignition Gears

12) Using a screwdriver, carefully push the rack actuator so the ignition would be in the "on" position (lights come on, but not started). 









13) Insert the gear with the notch of the gear facing downward and aligned parallel with the slots in the housing.  The two inner slots should then look perfectly aligned in place as shown in the pictures.







14) Then insert the retainer (thrust washer) with the notch facing down.
Next insert the lock and make sure you have all the positions. If not, remove it and try again.







15) Once you have all the positions correctly, then you will take the lock out again. The gear and washer may come with it.  That’s ok. Reassemble it again EXACTLY as the successful time but this time put the snap ring back in. Once all of that is in place, you can then insert the lock to make sure you have all the positions.





16) You may now connect the battery. Start the truck and make sure all the functions work correctly











17) Install the steering wheel and nut.













18) Install the horn pad.







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