Power steering gear box leaking at steering column to gear box

I am not familiar with the design of that steering gear but I expect there is an internal leak in the steering box that is allowing more pressure on the column shaft seal than it can cope with.

I believe such a leak would signal the need for a complete reseal and maybe an overhaul. Considering the age it wouldn't be surprising if the seals had deteriorated but equally seals can be damaged by corrosion or wear in shafts or bearings and for continued reliability these things must be checked.

You missed a spline when installing the pitman arm on the steering box. Park the truck straight and remove the arm. with the arm off, unlock steering column and point the steering wheel straight. Lock the steering column. Then reinstall the pitman arm on the steering box carefully matching the splines in the arm to the shaft on the steering box. that should be close to running straight while driving straight.

To Remove:

1. Before servicing the vehicle, refer to the precautions at the beginning of this section. NOTE: The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the SIR coil assembly (clock spring) to become uncentered, which may cause damage to the assembly.
   
2. Lock the steering column by installing the J42640 into the underside of the steering column.
3. Raise and support the vehicle.
4. Remove the tires and wheels.
5. Remove the power steering gear heat shield.
6. Remove or disconnect the following: CAUTION
   Failure to disconnect the intermediate shaft from the rack and pinion stub shaft can result in damage to the steering gear and/or intermediate shaft. This damage can cause loss of steering control, which could result in personal injury.
   
• Intermediate shaft lower pinch bolt and coupling from gear
• Pressure and return pipes from the gear
• Electrical connector, if equipped
  Stabilizer shaft links at lower control arms
• Remove the left stabilizer shaft insulator.
• Rotate the stabilizer shaft to access steering gear bolts.
• The outer tie rod retaining nuts.
• Using J24319-B separate the outer tie rods from the steering knuckles.
• Rack and pinion attaching bolts
• Rack and pinion assembly through the left wheel opening.
7. Transfer the outer tie rods if replacing the power steering gear.

To Install:

1. Install or connect the following:
   • Rack and pinion assembly through the left wheel opening and tighten the bolts to 70 ft. lbs. (95 Nm)
   • Electrical connector, if equipped
     Pressure and return lines to the steering gear and tighten the fittings to 22 ft. lbs. (30 Nm)
   • Heat shield and bolts. Tighten the bolts to 7 ft. Lbs. (10 N)
   • Install the left stabilizer shaft insulator.
2. Install stabilizer shaft Links to lower control arms
3. Intermediate shaft to the steering gear and tighten the pinch bolt to 35 ft. lbs. (47 Nm)
4. Install the outer tie rods to the steering knuckles.
5. Install the outer tie rods retaining nuts. torque the nuts to 22ft.lbs(30 Nm) plus an additional 180 degrees.
6. Install the tires and wheels.
7. Lower the vehicle.
8. Remove the steering column anti rotation pin from the steering column.
9. Fill and bleed the power steering system.
10. Adjust the front toe.

Lock the steering column by installing the Steering Column Anti Rotation Pin tool J 42640 into the underside of the steering column--Aurora


Steering gear mounting bolts--Aurora




Power Rack & Pinion Steering Gear Heat Shield Removal & Installation To Remove:

1. Raise and support the vehicle.
2. Remove or disconnect the following:
   • The stabilizer shaft links.
   • Rotate the stabilizer shaft downward.
   • The electrical harness clip.
   • Power steering gear heat shield mounting bolts.
   • The heat shield.

To Install:

1. Install the power steering gear heat shield.
2. Install or connect the following:
   • The mounting bolts And torque to 89in.lbs.(10 Nm)
   • The electrical harness clip.
   • Rotate the stabilizer shaft into position.
   • The stabilizer shaft links.
3. Lower the vehicle.

Figure of heat shield removed from above rack bolts with location shown

I dont think this car has a gear box,did you crash on that car to need to replace the steering column,you need to check first if the power steering pump has enogh pressure,the other part you need to check is the rack and pinion.

Removal Procedure

Notice: Do not rotate steering shaft after steering column has been removed. Damage to SIR components may occur.

Lock the steering column through the access hole in the steering column lower trim cover using the J 42640.
Remove the air cleaner assembly. Refer to Air Cleaner Outlet Resonator Replacement in Powertrain Management.Remove the intermediate shaft shield from the steering gear.Place a drain pan below the steering gear. Remove the pressure and the return hoses from the power steering gear. Cap or tape the ends of the hoses and the gear fittings in order to prevent dirt from entering the system.Remove the lower intermediate shaft coupling bolt. Draw alignment marks on the lower intermediate shaft coupling and the steering shaft. Remove the lower intermediate shaft coupling from the steering shaft. Remove the pitman arm. Refer to Pitman Arm Replacement.Remove the steering gear mounting bolts and the washers from the frame. Remove the steering gear.
Installation Procedure


Install the steering gear. Notice: Refer to Fastener Notice in Service Precautions. Install the power steering gear to the frame washers and the mounting bolts. Tighten Tighten the power steering gear to frame mounting bolts to 75 Nm (55 ft. lbs.). Install the pitman arm. Refer to Pitman Arm Replacement.Install the lower intermediate shaft to the power steering gear. Ensure that the alignment marks line up. Install the lower intermediate shaft coupling bolt. Tighten Tighten the lower intermediate shaft coupling bolt to 35 Nm (26 ft. lbs.). Install the pressure and the return hoses to the power steering gear. TightenTighten the pressure hose to 25 Nm (18 ft. lbs.) for the vehicle equipped with the 2.2L engines. Tighten the pressure hose to 30 Nm (22 ft. lbs.) for the vehicle equipped with the 4.3L engines. Tighten the return hose to 25 Nm (18 ft. lbs.). Install the intermediate shaft shield to the power steering gear. Install the air cleaner assembly. Refer to Air Cleaner Outlet Resonator Replacement in Powertrain Management. Unlock the steering column by removing the J 42640 from the steering column lower steering column trim cover access hole. Bleed the power steering system. Refer to Bleeding Power Steering System in Steering / Service and Repair.

would imagine their is just a oil seal their ,but whats causing the pressure behind the seal to make it leak ,yes i have repaired power steering boxes befoe now but on commercial vehicles 30+years ago ,principle still the same no doubt but i would advise you to get one from a scrapyard so vehicle is usable then when time permits have a play with the old one ,because you may find that its its cheaper to replace than repair with the cost of the spares

Dealer, but did you check the Power steering fluid level??or any leaks. There are two hose that connect to the gear box from the power steering pump. if the pump is low on fluid you lose your power steering, if the hose has a leak or it blew and lost the power steering fluid then you lost your power steering again. 
Check the fluid level to the power steering pump and any leaks or broken hose to the gear box.
Keep me posted, be glad to help and good luck.

if fluid is flowing out the bellows, you need to replace the steering rack assembly. There is no fluid in the area of the inner tie rod. The seal is just before the tie rod.

Steering Gear
The power rack and pinion steering gear is serviced as a power steering short rack (3L547). The front wheel spindle tie rods (3280) and tie rod ends (3A130) are serviced individually. -------------------------------------------------------------------------------------------

• The power rack and pinion steering gear incorporates quick connect fittings for the power steering pressure hose (3A719) and power steering return hose (3A713) that allow the lines to swivel. This is normal and does not indicate loose fittings.
• If the fittings leak, check to make sure they are tightened to 14-20 Nm (10-14 lb-ft). Do not overtighten.
• If the leak is not corrected, replace the fitting seals.

-------------------------------------------------------------

-----------------------------------------------------
Section 11-02: Steering System, Power 1997 Windstar Workshop Manual
REMOVAL AND INSTALLATION Tie Rod End Steering Gear Installed
Removal

1. Remove and discard cotter pin and nut from worn tie rod end (3A130).
   

1. Disconnect tie rod end from front wheel knuckle (3K185), using Tie Rod End Remover TOOL-3290-D or equivalent.
   

1. Hold tie rod end with a wrench and loosen tie rod end jam nut.
   

1. Note depth to which tie rod end was located by using the jam nut as a marker. Grip tie rod end with a pair of suitable pliers and remove tie rod end from front wheel spindle tie rod (3280).
   

---------------------------------------------------------------------------------------
11-02: Steering System, Power 1997 Windstar Workshop Manual
REMOVAL AND INSTALLATION Steering Gear Removal

1. Raise vehicle on a twin post hoist and remove wheel and tire assemblies. Refer to Section 00-02 .
   
   
   
   
   

1. Support vehicle with jackstands under front jack pads.
   

1. Remove tie-rod end cotter pins and nuts and remove tie rod ends (3A130) from front wheel knuckle (3K185). Refer to Section 04-01 .
   

1. Remove front stabilizer bar (5482). Refer to Section 04-01 .
   

1. Disconnect heated oxygen and catalyst monitor sensors.
   

1. Support flex pipe.
   

1. Remove bolts and disconnect flex pipe from the converter.
   

1. Raise dash opening steering column opening weather seal (3513) (secondary) above the steering gear housing (3548).
   

1. Remove pinch bolt retaining steering column intermediate shaft coupling (3A525) to power steering gear input shaft and control (3D517) and disconnect the shaft.
   

1. Remove nuts from steering gear-to-front subframe retaining bolts. Remove bolts.
   

1. Remove rear subframe-to-body retaining bolts.
   

1. Lower twin post hoist carefully until rear of subframe (5R003) separates from body, approximately four inches.
   

1. Remove heat shield band and fold shield down.
   

1. Rotate power rack and pinion steering gear to clear bolts from front subframe (5C145) and pull left to facilitate line fitting removal.
   

1. Place a drain pan under vehicle and remove line fittings.
   

1. Remove power rack and pinion steering gear through LH wheel well.
   

1. Remove and discard the O-rings.
   

Installation

1. Install new Teflon® O-rings on line fittings as outlined.
   

1. Place steering gear retaining bolts in steering gear housing.
   

1. Install power rack and pinion steering gear through LH wheel well.
   

1. Install power steering line fittings to power rack and pinion steering gear.
   

1. Position power rack and pinion steering gear into front subframe.
   

1. Install ******** heat shield.
   

1. Install tie-rod ends to front wheel knuckle. Install nuts and new cotter pins. Refer to Section 04-01 .
   

1. Install LH front stabilizer bar. Refer to Section 04-01 .
   

1. Install steering gear to subframe mounting nuts. Tighten to 115-135 Nm (85-99 lb-ft).
   

1. Raise hoist until rear subframe contacts body.
   

1. Install rear subframe to body retaining bolts. Tighten to 113-153 Nm (83-112 lb-ft).
   

1. Install exhaust system flex tube to dual converter Y pipe (5F250) and remove flex tube support.
   

1. Connect heated oxygen and catalyst monitor sensors.
   

1. Install tire and wheel assemblies. Tighten lug nuts (1012) to 115-142 Nm (85-104 lb-ft).
   

1. Using a new pinch bolt, install the steering column intermediate shaft coupling on the power steering gear input shaft and control and the lower steering column shaft. Tighten the pinch bolt to 34-46 Nm (25-33 lb-ft).
   

1. Position steering column opening weather seal (secondary) over the steering gear housing. Tighten nuts to 4.5-6.3 Nm (40-55 lb-in).
   

1. Remove jackstands and lower vehicle.
   

1. Fill power steering oil reservoir (3A697) with Premium Power Steering Fluid E6AZ-19582-AA or equivalent meeting Ford specification ESW-M2C33-F. Refer to Section 11-00 .
   

1. Check system for leaks and proper operation.
   
   

The gear box is a common problem on this model. That would be the place I would start. A cheap, temporary fix is to go to your local parts store and ask for Lucas Power Steering Stop-Leak. It will buy you some time.

Believe it or not there are some problems you should take to the dealer. It never was the gear box, its a defective steering column bushing. That problem had a factory notice and the dealer would have diagnosed it immediately an fixed it free parts +$40.install. Tahoes get that problem.