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Steering System-General Information Ford Cutaway E350

Manual & Power Steering 18 illustrations ~5116 words

GENERAL SPECIFICATIONS

ItemSpecification
Lubricants
MERCON® Multi-Purpose (ATF) Transmission Fluid XT-2-QDXMERCON®
Power Steering Gear
Turning effort31 Nm (23 lb-ft)
Turns lock-to-lock4
Meshload0.9 Nm (8 lb-in)
Power Steering Purge Vacuum68-85 kPa (20 - 25 in/hg)
Power Steering Pump
Flow10.6 - 12.0 liters/minute (2.8 - 3.2 gpm) Fluid @ 74°-80°C (165°-176°F) Engine at 1,500 rpm
Minimum capacity5.3 liters/minute (1.4 gpm) Fluid @ 74°-80°C (165°-176°F) Engine at idle Pressure at 5,171 kPa (750 psi)
Pressure1,034 kPa (150 psi) Fluid @ 74°-80°C (165°-176°F) Engine at 1,500 rpm
Relief pressure 15,200 and 18,000 GVWR9,000-9,900 kPa (1,300-1,430 psi)
Relief pressure 20,50017,000 kPa (2,465 psi)

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

DescriptionNm
Sector shaft lock nut26-35
Sector shaft arm drag link nut77-103

TORQUE SPECIFICATIONS

The steering system consists of the following

Scheme 1

Scheme 1: Steering System
Scheme 1: Steering System

For additional information on the power steering oil reservoir (3A697), refer to POWER STEERING .

For additional information on the steering wheel and column assembly, refer to STEERING COLUMN .

For additional information on the power steering fluid lines, refer to POWER STEERING .

For additional information on the front wheel spindles (3105), refer to FRONT SUSPENSION .

For additional information on the power steering fluid cooler (3D746), refer to POWER STEERING .

For additional information on the power steering pump (3A674), refer to POWER STEERING . .

For additional information on the steering gear (3504), refer to POWER STEERING .

For additional information on the steering linkage, refer to STEERING LINKAGE .

Special Tool(s)

SPECIAL TOOL(S) Dial Thermometer 0-220°F 023-R0007 or equivalent 73III Automotive Meter 105-R0057 or equivalent Power Steering Analyzer 211-F001 (014-00207) or equivalent Gauge, Spring Tension 211-034 (T74P-3504-Y) DIS/EDIS Tach Adapter 418-F102 (007-00061) or equivalent Steering Arm Remover 211-003 (T64-3590F) or equivalent

Scheme 2

Scheme 2: Special Tool(s)
Scheme 2: Special Tool(s)

Scheme 3

Scheme 3
Scheme 3

Scheme 4

Scheme 4
Scheme 4

Scheme 5

Scheme 5
Scheme 5

Scheme 6

Scheme 6
Scheme 6

Scheme 7

Scheme 7
Scheme 7

Material

ItemSpecification
MERCON® Multi-Purpose ATF Transmission Fluid XT-2-QDXMERCON®

MATERIAL SPECIFICATION

Scheme 8

Scheme 8: Inspection and Verification
Scheme 8: Inspection and Verification
  1. Verify the customer concern.
  2. Visually inspect for obvious signs of mechanical damage. VISUAL INSPECTION CHART Mechanical Fluid level Tire pressure Tires Drive belt Drive belt tensioner Steering column alignment Tie rod ends Suspension components Steering column shaft U-joints Intermediate shaft bolts Power steering reservoir baffle Power steering reservoir filter Power steering pressure lines, fittings or O-rings Power steering return hoses and clamps Steering gear Power steering pump
  3. Inspect the power steering fluid for the following conditions: Aerated or foamy: Purge the power steering system. Refer to «POWER STEERING SYSTEM PURGING»(/ford/cutaway-e350/2004-2007/remont/manual-power-steering/#steering-system-general-information) . Overheating or contamination: Flush the power steering system. Refer to «POWER STEERING SYSTEM FILLING»(/ford/cutaway-e350/2004-2007/remont/manual-power-steering/#steering-system-general-information) .
  4. Check the power steering system for fluid leaks. Check the power steering fluid level. NOTE: It may be necessary to add power steering fluid to achieve the correct level. With the ignition OFF: Wipe off the power steering pump, power steering pressure hose, power steering return hose, power steering fluid cooler, hose assembly and steering gear. CAUTION: Do not hold the steering wheel at the stops for an extended amount of time. Damage to the power steering pump can occur. Start the engine and turn the steering wheel from stop-to-stop several times and check for leaks.
  5. Inspect the power steering pressure and return hoses, fittings and O-rings for leaks. If a leak is detected at a power steering pressure or return hose, install a new hose. Refer to «POWER STEERING»(/ford/cutaway-e350/2004-2007/remont/manual-power-steering/#power-steering-system) . If a leak is detected between a fitting nut, seal the fitting nut using Teflon® joint seal. If a leak is detected at a fitting, tighten to specification. If leak is still evident, visually inspect the fittings, O-rings and Teflon® seals. Install new as necessary. Refer to «POWER STEERING»(/ford/cutaway-e350/2004-2007/remont/manual-power-steering/#power-steering-system) . If a leak is detected at the power steering reservoir, install a new reservoir. Refer to «POWER STEERING»(/ford/cutaway-e350/2004-2007/remont/manual-power-steering/#power-steering-system) . If a leak is detected at a constant tension spring clamp, verify that the hose is fully installed on the fitting and that the hose clamp is correctly positioned. If the leak remains, install a new screw clamp. If a leak is detected at a screw clamp joint, tighten the screw clamp. If the leak remains, inspect the tube end and install a new hose. Refer to «POWER STEERING»(/ford/cutaway-e350/2004-2007/remont/manual-power-steering/#power-steering-system) . If a leak is detected at the power steering pump, install a new power steering pump. Refer to «POWER STEERING»(/ford/cutaway-e350/2004-2007/remont/manual-power-steering/#power-steering-system) .
  6. Inspect the power steering gear for leaks. If a leak is detected at the power steering gear, install a new power steering gear. Refer to «POWER STEERING»(/ford/cutaway-e350/2004-2007/remont/manual-power-steering/#power-steering-system) .
  7. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
  8. If the cause is not visually evident, verify the symptom and GO to «SYMPTOM CHART»(/ford/cutaway-e350/2004-2007/remont/manual-power-steering/#steering-system-general-information__symptom-chart) .

Drift/Pull

Pull is described as a tugging sensation, felt by the hands on the steering wheel, that must be overcome to keep the vehicle going straight.

Drift describes what a vehicle with this condition does with the hands off the steering wheel.

  1. A vehicle-related drift/pull, on a flat road, can cause a consistent deviation from the straight-ahead path and require constant steering input in the opposite direction to counteract the effect.
  2. Drift/pull can be induced by conditions external to the vehicle (for example, wind or road camber).

Excessive Steering Wheel Play

Excessive steering wheel play is a condition in which there is too much steering wheel movement before the wheels move. A small amount of steering wheel free play is considered normal.

Feedback

Feedback is a roughness felt in the steering wheel when the vehicle is driven over rough pavement.

Hard Steering or Lack of Assist

Hard steering or lack of assist is experienced when the steering wheel effort exceeds specifications. Hard steering can remain constant through the full turn or occur near the end of a turn. It is important to know the difference between hard steering/lack of assist and binding.

Hard steering or lack of assist can result from either hydraulic or mechanical conditions. It is extremely important to know if this concern occurs during driving or during high-effort parking maneuvers.

Nibble

Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various road surfaces and observed by the driver as small rotational oscillations of the steering wheel.

Poor Returnability/Sticky Steering

Poor returnability and sticky steering is used to describe the poor return of the steering wheel to center after a turn, or the steering correction, is completed.

Shimmy

Shimmy, as observed by the driver, is large, consistent, rotational oscillations of the steering wheel resulting from large, side-to-side (lateral) tire/wheel movements.

Shimmy is usually experienced near 64 km/h (40 mph), and can begin or be amplified when the tire contacts pot holes or irregularities in the road surface.

Wander

Wander is the tendency of the vehicle to require frequent, random left and right steering wheel corrections to maintain a straight path down a level road.

Symptom Chart

ConditionPossible SourcesAction
Steering system noiseLow fluid level. Fluid aeration. Steering gear. Power steering pump. Loose or damaged steering linkage. Loose or damaged suspension component(s). Steering column. Steering column boot bearing. Intermediate shaft. Loose dash boot seal.GO to PINPOINT TEST A .
Steering is very difficult/very easySeized intermediate shaft U-joints. Damaged, fractured steering column bearing(s). Steering gear. Power steering pump. Power steering hoses. Binding dash boot seal.GO to PINPOINT TEST B .
Excessive steering wheel playSteering gear. Steering column. Steering column intermediate shaft. Steering linkage. Ball joints. Strut bearing plate (if applicable).GO to PINPOINT TEST C .
Steering system drift/pull/wanderTire pressure. Wheel alignment. Steering gear. Unevenly loaded vehicle. Steering column intermediate shaft. Frame alignment.CORRECT the vehicle loading as necessary. GO to PINPOINT TEST D .
FeedbackLoose, worn or damaged tie rod.GO to Component Tests, TIE-ROD ARTICULATION TORQUE .
Loose, worn or damaged tie-rod ends.GO to Component Tests, STEERING LINKAGE .
Loose or damaged steering gear insulators or bolts.INSTALL new steering gear insulators or bolts if necessary, or TIGHTEN the bolts as needed.
Loose lower steering column shaft U-joint bolts.INSTALL new bolts or TIGHTEN the bolts. REFER to STEERING COLUMN .
Loose suspension bushings, fasteners, ball joints or strut bearing plate (if applicable).INSTALL new components as necessary. REFER to FRONT SUSPENSION .
Worn or damaged steering column bearing(s).INSTALL new steering column bearings(s). REFER to WHEELS & TIRES .
Poor returnability/sticky steeringBinding lower steering column shaft U-joints.INSTALL a new lower steering column shaft. REFER to STEERING COLUMN .
Loose, worn or damaged front wheel knuckle tie rod.GO to Component Tests, TIE-ROD ARTICULATION TORQUE .
Loose, worn or damaged tie-rod ends.GO to Component Tests, STEERING LINKAGE .
Suspension components.REFER to SUSPENSION SYSTEM-GENERAL INFORMATION for the suspension diagnoses and testing.
Binding steering column bearing(s).INSTALL new steering column bearings(s). REFER to STEERING COLUMN .
Binding dash boot seal.
ShimmyLoose, worn or damaged tie-rod end.GO to Component Tests, STEERING LINKAGE .
Loose, worn or damaged tie-rod.GO to Component Tests, TIE-ROD ARTICULATION TORQUE .
Suspension components.REFER to SUSPENSION SYSTEM-GENERAL INFORMATION for the suspension diagnosis and testing.

STEERING SYSTEM SYMPTOM CHART

PINPOINT TEST A: STEERING SYSTEM NOISE

  1. A1 CHECK FOR MECHANICAL NOISE Test drive the vehicle to verify the steering system noise. Does the steering system make a clunk noise? Yes : CHECK for loose, worn or damaged tie rod ends. REFER to Component Tests, «STEERING LINKAGE»(/ford/cutaway-e350/2004-2007/remont/manual-power-steering/#steering-system-general-information__steering-linkage) . CHECK for loose or worn steering gear isolators (if applicable). INSTALL new isolators if necessary. REFER to «POWER STEERING»(/ford/cutaway-e350/2004-2007/remont/manual-power-steering/#power-steering-system) . If the noise is from the steering column, CHECK the steering column intermediate shaft for grounding through the body and repair as necessary. If the noise is from the steering column boot bearing, INSTALL a new steering column boot bearing. REFER to «STEERING COLUMN»(/ford/cutaway-e350/2004-2007/remont/steering-column/#steering-column) . If the noise is from the suspension components, INSTALL new suspension components as necessary. REFER to «FRONT SUSPENSION»(/ford/cutaway-e350/2004-2007/remont/suspension-front/#front-suspension) . If the noise is from loose, worn or damaged intermediate shaft U-joint(s), INSTALL a new lower steering column shaft. REFER to «STEERING COLUMN»(/ford/cutaway-e350/2004-2007/remont/steering-column/#steering-column) . No : If a squeak is present in the steering column, REPAIR the steering column mountings or align the steering column as necessary. REFER to «STEERING COLUMN»(/ford/cutaway-e350/2004-2007/remont/steering-column/#steering-column) . For all other concerns, GO to A2.
  2. A2 VERIFY THE CONCERN NOTE: Make sure that the vehicle is on a flat dry surface, the transmission is in PARK and that the windows are rolled up. NOTE: Some power steering noise is expected. If in doubt of the acceptability of the noise level, evaluate another vehicle of the same model and powertrain. Key in START position. Turn the steering wheel one-half turn off-center to the right then one-half turn off-center to the left. Is the power steering noisy? Yes : If a grunt noise is present, verify the steering column boot is OK and the exhaust system is not grounding out. If a moan is present, verify that the tie-rod ends and ball joints are OK. GO to A3. No : If a squeal is present, INSPECT and INSTALL a new engine drive belt or belt tensioner as necessary. REFER to «ENGINE SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-system-general-information) . If the steering system noise is a hiss or whistle, INSPECT the steering column boot at the dash panel. REPAIR or INSTALL a new boot as necessary. REFER to «STEERING COLUMN»(/ford/cutaway-e350/2004-2007/remont/steering-column/#steering-column) . INSPECT the steering gear input shaft and valve for wear or damage. REFER to «POWER STEERING»(/ford/cutaway-e350/2004-2007/remont/manual-power-steering/#power-steering-system) . INSPECT the power steering gear, intermediate shaft and power steering lines and hoses for grounding to the body and repair as necessary. INSPECT for openings or missing plugs in the instrument panel cowl and repair as necessary. If there are no missing plugs or openings in the cowl, grounded power steering gear, intermediate shaft or power steering lines or hoses, GO to A6 .
  3. A3 CHECK FOR COLD START NOISE NOTE: Some noise during an extremely cold start -25.5°C (-14°F) is normal and should improve as the steering system warms up (usually within 60 seconds). Key in START position. Verify the noise condition. Is the noise present only during cold start up? Yes : CHECK for contamination in the power steering reservoir screen. FLUSH the power steering system as necessary. REFER to «POWER STEERING SYSTEM FLUSHING»(/ford/cutaway-e350/2004-2007/remont/manual-power-steering/#steering-system-general-information) . TEST the system for normal operation. No : GO to A4.
  4. A4 INSPECT THE POWER STEERING FLUID Key in OFF position. With the engine OFF, inspect the power steering fluid for aeration. Is the power steering fluid foamy or aerated? Yes : GO to A5. No : PURGE the power steering system. REFER to «POWER STEERING SYSTEM PURGING»(/ford/cutaway-e350/2004-2007/remont/manual-power-steering/#steering-system-general-information) . If a whine or a moan is still present, INSTALL a new power steering pump. REFER to «POWER STEERING»(/ford/cutaway-e350/2004-2007/remont/manual-power-steering/#power-steering-system) . If a grunt is still present, INSTALL a new power steering gear. REFER to «POWER STEERING»(/ford/cutaway-e350/2004-2007/remont/manual-power-steering/#power-steering-system) .
  5. A5 CHECK THE POWER STEERING FLUID LEVEL WITH THE ENGINE ON AND OFF NOTE: Record the vacuum level when the pump noise occurs with no steering input. Vacuum level should be greater than 10 inches of mercury with CM pump and 15 inches of mercury on the CIII pump. Key in START position. With the engine running, inspect the power steering fluid level. Key in OFF position. With the engine off, inspect the power steering fluid level. Does the power steering fluid level change with the engine off? Yes : PURGE the power steering system. REFER to «POWER STEERING SYSTEM PURGING»(/ford/cutaway-e350/2004-2007/remont/manual-power-steering/#steering-system-general-information) . No : GO to A6.
  6. A6 CHECK THE POWER STEERING PUMP NOTE: Do not turn the steering wheel to either the right or left stop. Power steering relief noise will occur and is normal at the stop positions. Key in START position. With the engine running, rotate the steering wheel 90 degrees to the left then to the right. Does the frequency of the hiss change between the left and right positions? Yes : INSTALL a new power steering gear. REFER to «POWER STEERING»(/ford/cutaway-e350/2004-2007/remont/manual-power-steering/#power-steering-system) . No : INSTALL a new power steering pump. REFER to «POWER STEERING»(/ford/cutaway-e350/2004-2007/remont/manual-power-steering/#power-steering-system) .

PINPOINT TEST B: STEERING IS VERY DIFFICULT/VERY EASY

  1. B1 CHECK THE STEERING COLUMN BEARINGS AND THE INTERMEDIATE SHAFT NOTE: Be sure to keep the clockspring centered when disconnecting the intermediate shaft. Refer to «SUPPLEMENTAL RESTRAINT SYSTEM»(/ford/cutaway-e350/2004-2007/remont/airbag/#supplemental-restraint-system) . Check the steering column and intermediate shaft for grounding. Disconnect the steering column intermediate shaft at the steering column. Verify that the intermediate shaft universal joints do not bind and move freely and that the steering column bearing rotates freely. Are the steering column bearing and intermediate shaft universal joints OK? Yes : GO to B2. No : If the steering column or the intermediate shaft are grounding, repair as necessary. If the steering column bearings or the intermediate shaft are binding. INSTALL a new intermediate shaft or steering column. REFER to «STEERING COLUMN»(/ford/cutaway-e350/2004-2007/remont/steering-column/#steering-column) .
  2. B2 CHECK THE FRONT BALL JOINTS AND UPPER STRUT BEARING Check that the front ball joints and upper strut bearing move freely and are not binding or sticking. Refer to «SUSPENSION SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/suspension-front/#suspension-syste-general-information) . Are the front ball joints and upper strut bearing OK? Yes : GO to B3. No : INSTALL new ball joints or upper strut bearing as necessary. REFER to «FRONT SUSPENSION»(/ford/cutaway-e350/2004-2007/remont/suspension-front/#front-suspension) .
  3. B3 MONITOR ENGINE RPM CHANGES NOTE: Make sure that the vehicle is on a flat, dry surface. Key in START position. CAUTION: Do not hold the steering wheel at the stops for an extended amount of time. Damage to the power steering pump can occur. Turn the steering wheel once to the left stop position and then to the right stop position. Note the engine rpm during the turns. Does the engine rpm change when turning the steering wheel? Yes : If no power steering assist is present and the engine rpm changes, INSTALL a new steering gear. REFER to «POWER STEERING»(/ford/cutaway-e350/2004-2007/remont/manual-power-steering/#power-steering-system) . If left-to-right variation is present, INSTALL a new steering gear. REFER to «POWER STEERING»(/ford/cutaway-e350/2004-2007/remont/manual-power-steering/#power-steering-system) . If no power steering assist is present and the engine rpm does not change, INSTALL a new power steering pump. REFER to «POWER STEERING»(/ford/cutaway-e350/2004-2007/remont/manual-power-steering/#power-steering-system) . If excessive effort is required in one or both directions, INSTALL a new power steering pump. REFER to «POWER STEERING»(/ford/cutaway-e350/2004-2007/remont/manual-power-steering/#power-steering-system) . No : CARRY OUT the Pump Flow and Pressure Test. REFER to «COMPONENT TESTS»(/ford/cutaway-e350/2004-2007/remont/manual-power-steering/#steering-system-general-information) .

PINPOINT TEST C: EXCESSIVE STEERING WHEEL PLAY

  1. C1 CHECK THE STEERING COLUMN BEARING Inspect the steering column mounting fasteners and bearing for looseness. Are the fasteners and bearing OK? Yes : GO to C2. No : TIGHTEN the steering column mounting fasteners or INSTALL a new steering column. REFER to «STEERING COLUMN»(/ford/cutaway-e350/2004-2007/remont/steering-column/#steering-column) .
  2. C2 CHECK THE STEERING LINKAGE FOR LOOSENESS Carry out the Steering Linkage component test. Refer to «COMPONENT TESTS»(/ford/cutaway-e350/2004-2007/remont/manual-power-steering/#steering-system-general-information) . Is the steering linkage OK? Yes : REFER to «SUSPENSION SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/suspension-front/#suspension-syste-general-information) to diagnose the suspension components. No : INSTALL new steering linkage as necessary. REFER to «STEERING LINKAGE»(/ford/cutaway-e350/2004-2007/remont/steering-linkage/#steering-linkage) .

PINPOINT TEST D: STEERING SYSTEM DRIFT/PULL/WANDER

  1. D1 CHECK FOR TIRE PULL Rotate the front wheel and tire assemblies side-to-side. Refer to «WHEELS & TIRES»(/ford/cutaway-e350/2004-2007/remont/wheel-tire-system/#tires-wheels) . Carry out a road test on a smooth, flat road. Does the vehicle drift/pull? Yes : If vehicle pulls in the opposite direction, GO to If vehicle pulls in original direction, GO to D3 . No : Concern has been corrected.
  2. D2 ROTATE THE WHEEL AND TIRE ASSEMBLIES FRONT TO REAR Rotate the front wheel and tire assemblies front to rear. Refer to «WHEELS & TIRES»(/ford/cutaway-e350/2004-2007/remont/wheel-tire-system/#tires-wheels) . Carry out a road test on a smooth, flat road. Does the vehicle drift/pull? Yes : GO to D3. No : Concern has been corrected.
  3. D3 CHECK THE STEERING COLUMN INTERMEDIATE SHAFT NOTE: Be sure to keep the clockspring centered when disconnecting the intermediate shaft. Refer to «SUPPLEMENTAL RESTRAINT SYSTEM»(/ford/cutaway-e350/2004-2007/remont/airbag/#supplemental-restraint-system) . Check the steering column and intermediate shaft for grounding. Disconnect the steering column intermediate shaft at the steering column. Inspect the steering column intermediate shaft U-joints for looseness or wear. Are the steering column intermediate shaft universal joints OK? Yes : GO to D4. No : INSTALL a new steering column intermediate shaft. REFER to «STEERING COLUMN»(/ford/cutaway-e350/2004-2007/remont/steering-column/#steering-column) . .
  4. D4 CHECK THE STEERING GEAR MOUNTING Check the steering gear mounts for looseness or wear. Are the steering gear mounts OK? Yes : GO to D5. No : INSTALL new steering gear mounts. REFER to «POWER STEERING»(/ford/cutaway-e350/2004-2007/remont/manual-power-steering/#power-steering-system) .
  5. D5 CHECK THE STEERING GEAR Carry out the Steering Gear Valve component test. Refer to «COMPONENT TESTS»(/ford/cutaway-e350/2004-2007/remont/manual-power-steering/#steering-system-general-information) . Is the steering gear valve OK? Yes : GO to D6. No : REPAIR or INSTALL a new steering gear. REFER to «POWER STEERING»(/ford/cutaway-e350/2004-2007/remont/manual-power-steering/#power-steering-system) .
  6. D6 CHECK THE SUSPENSION COMPONENTS Check for loose or worn suspension components. Refer to «FRONT SUSPENSION»(/ford/cutaway-e350/2004-2007/remont/suspension-front/#front-suspension) or «REAR SUSPENSION»(/ford/cutaway-e350/2004-2007/remont/suspension-rear/#rear-suspension) . Are the suspension components OK? Yes : GO to D7. No : INSTALL new suspension components. REFER to «FRONT SUSPENSION»(/ford/cutaway-e350/2004-2007/remont/suspension-front/#front-suspension) or «REAR SUSPENSION»(/ford/cutaway-e350/2004-2007/remont/suspension-rear/#rear-suspension) .
  7. D7 CHECK THE WHEEL ALIGNMENT NOTE: The vehicle will tend to pull toward the side with the least positive caster and the most positive camber. Using a suitable alignment system, measure the wheel alignment settings. Refer to «SUSPENSION SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/suspension-front/#suspension-syste-general-information) . Are the alignment settings within specifications? Yes : CHECK for correct frame alignments. REFER to «FRONT END BODY PANELS»(/ford/cutaway-e350/2004-2007/remont/exterior-body-panels/#body-panel-system-front-end-body-panels) . No : ADJUST the alignment angles to specifications. DO NOT exceed specifications. TEST the system for normal operation.

Steering Linkage

  1. With the vehicle on the ground and the parking brake applied, start the vehicle and carry out the following: Have an assistant rotate the steering wheel back and forth 360 degrees and watch for relative motion of the studs in the steering linkage ball sockets. Watch for loose steering gear mounting.
  2. An additional check is with the KOEO and the front wheels raised off the ground, grasp the wheel at the front and rear and watch for excessive play or binding in the joints while trying to steer the wheels.
  3. Install new components if necessary. Tighten any worn, damaged, or loose components.

Turning Effort Test

Note. Make sure that the front wheels are correctly aligned and the tire pressure is correct before checking the steering effort.

  1. Park the vehicle on dry concrete and set the parking brake.
  2. Insert a thermometer into the power steering oil reservoir.
  3. Idle the engine for 2 to 3 minutes. Turn the steering wheel from stop-to-stop several times to warm the fluid to 50-60°C (122-140°F).
  4. With the engine running, attach the spring scale to the rim of the steering wheel.
  5. Measure the pull required to turn the steering wheel one complete revolution in each direction.

Pump Flow and Pressure Test

WARNINGDo not touch the flowmeter during the test procedure, or severe burns and serious injury can occur. Failure to follow these instructions may result in personal injury.
  1. Install the power steering analyzer at the high pressure port of the power steering pump. Make sure the power steering analyzer gate valve is fully open.
  2. Place a dial thermometer in the power steering pump reservoir.
  3. Check the power steering fluid level. If necessary, add specified power steering fluid.
  4. Install a digital tachometer.
  5. Start the engine. Place the transmission in NEUTRAL. Set the parking brake. Raise the power steering fluid temperature to 74-80°C (165-175°F) by rotating the steering wheel fully to the left and right several times.
  6. With the steering wheel in the straight-ahead position, set the engine speed to 2,100 rpm. Record the flow rate and pressure readings. If the flow rate is below the flow rate specification, continue with the test procedure. If the pressure reading is above the maximum pressure specification, check the power steering hoses for kinks and restrictions.
  7. Partially close the gate valve to obtain 750 psi. Set the engine speed at idle. Record the flow rate. If the flow is less than the specified flow rate, install a new power steering pump.
  8. Completely close and partially open the gate valve 3 times. Record the pressure relief valve actuation pressure reading. If the pressure does not meet the relief pressure specification, then install a new power steering pump.
  9. Set engine speed to 2,100 rpm. Record the flow rate. If the flow rate varies more than 3.785 liters/minute (1 gallon/minute) from the initial flow rate reading, install a new power steering pump.
  10. Set the engine speed at idle. Turn (or have an assistant turn) the steering wheel to the left and right stops. Record flow rate and pressure readings at the stops. The pressure reading at both stops should be nearly the same as the maximum pump relief pressure. The flow rate should drop below 1.9 liters/minute (0.5 gallons/minute). If the pressure does not reach the maximum pump relief pressure or the flow rate does not drop below the specified value, excessive internal leakage is occurring. Install a new steering gear as necessary. Refer to «POWER STEERING»(/ford/cutaway-e350/2004-2007/remont/manual-power-steering/#power-steering-system) .
  11. Turn (or have an assistant turn) the steering wheel slightly in both directions and release quickly while watching the pressure gauge. The pressure reading should move from the normal back pressure reading and snap back as the steering wheel is released. If the pressure returns slowly or sticks, the rotary valve in the steering gear is sticking or the steering column is binding. Check the steering column and linkages before repairing the steering gear.

Tie-Rod Articulation Torque

Note. This check may be done with the steering gear on or off the vehicle.

  1. Disconnect the tie-rod end from the front wheel knuckle. Refer to «POWER STEERING»(/ford/cutaway-e350/2004-2007/remont/manual-power-steering/#power-steering-system) .
  2. Move the front wheel knuckle tie rod back and forth 3 times.
  3. Hook a spring scale over the tie-rod end or the threaded portion of the front wheel knuckle tie rod and measure the force required to move the front wheel knuckle tie rod. Refer to General Specifications, «TIE-ROD ARTICULATION TORQUE»(/ford/cutaway-e350/2004-2007/remont/manual-power-steering/#steering-system-general-information__tie-rod-articulation-torque) .
  4. If the force required to move the front wheel knuckle tie rod does not meet the specifications, install a new front wheel knuckle tie rod. Refer to «POWER STEERING»(/ford/cutaway-e350/2004-2007/remont/manual-power-steering/#power-steering-system) .

Steering Gear Valve

  1. With the vehicle in motion, place the transmission in NEUTRAL and turn the engine OFF. If the vehicle does not pull with the engine OFF, repair or install a new steering gear. Refer to «POWER STEERING»(/ford/cutaway-e350/2004-2007/remont/manual-power-steering/#power-steering-system) .
  2. If the vehicle pulls with the engine OFF, switch the right side front wheel to the left side of the vehicle and the left side front wheel to the right side of the vehicle.
  3. If the vehicle pulls to the opposite side, switch the front wheels with the rear wheels keeping them on the same side of the vehicle.
  4. If the vehicle pull direction does not change, check the front suspension components, wheel alignment and frame alignment. Refer to «SUSPENSION SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/suspension-front/#suspension-syste-general-information) or an appropriate frame dimensions article.

Vertical Inspection

Note. Checking the steering linkage components for vertical (up and down) deflection is preferred, however it may be necessary to check some steering linkage components for lateral (side-to-side) deflection due to lack of clearance for the dial indicator. Outer tie-rod ends should always be checked for vertical deflection . Using a vice grip style, flexible arm dial indicator (such as Snap On® stock # GA3634) is suggested.

Note. The steering linkage component ball studs are spring loaded and will normally have a small amount of vertical deflection when the spring is compressed. However, excessive vertical deflection of the studs relative to the sockets may indicate excessive wear.

  1. Turn the steering wheel to the straight-ahead position and turn the ignition switch to the OFF position.
  2. With the vehicle in NEUTRAL, position it on a hoist. Refer to appropriate Jack and Lifting in General Information article .
  3. If necessary, remove the wheel and tire. Refer to «TIRES & WHEELS»(/ford/cutaway-e350/2004-2007/remont/wheel-tire-system/#tires-wheels) article .
  4. Install the dial indicator as shown. Attach the vise grip/flexible arm to the nut of the steering linkage component being tested or the component that the steering linkage ball stud seats into. Position the flexible arm so that the dial indicator is positioned on the center of the steering linkage component cap and lock the flexible arm.
  5. Grasp the steering linkage component forging near the ball stud, push upward, pull downward, and then release it. This will allow the steering linkage component to be in a relaxed position when measuring.
  6. Zero the dial indicator.
  7. Using a suitable prying device (approximately 457 mm [18 in] long), pry on the steering linkage component forging while observing the deflection of the dial indicator pointer. Only apply moderate force. Do not move the vehicle suspension.
  8. If the vertical deflection exceeds 2.30 mm (0.09 in), install a steering linkage component. Refer to «STEERING LINKAGE»(/ford/cutaway-e350/2004-2007/remont/steering-linkage/#steering-linkage) article .

Lateral Inspection

Note. Checking the steering linkage components for vertical (up and down) deflection is preferred, however it may be necessary to check some steering linkage components for lateral (side-to-side) deflection due to lack of clearance for the dial indicator. Outer tie-rod ends should always be checked for vertical deflection. Using a vice grip style, flexible arm dial indicator (such as Snap On® stock # GA3634) is suggested.

  1. Turn the steering wheel to the straight-ahead position and turn the ignition switch to the OFF position.
  2. With the vehicle in NEUTRAL, position it on a hoist. Refer to appropriate Jack and Lifting in General Information article .
  3. Install the dial indicator. Attach the vise grip/flexible arm to the nut of the steering linkage component being tested or the component that the steering linkage ball stud seats into. Position the flexible arm so that the dial indicator is positioned on the end of steering linkage housing and lock the flexible arm.
  4. Have an assistant grasp the tire and move the steering linkage from side-to-side. Observe and record the deflection measured with the dial indicator.
  5. If the lateral deflection exceeds 1.30 mm (0.05 in), install a new steering linkage component. Refer to «STEERING LINKAGE»(/ford/cutaway-e350/2004-2007/remont/steering-linkage/#steering-linkage) article .
ItemSpecification
MERCON® Multi-Purpose ATF Transmission Fluid XT-2-QDXMERCON®

MATERIAL SPECIFICATION

Procedure

WARNINGDo not mix oil types. Any mixture or any unapproved oil can lead to seal deterioration and leaks. A leak can ultimately cause loss of fluid, which can result in a loss of power steering assist. Failure to follow these instructions may result in personal injury.
  1. Remove the power steering fluid reservoir cap.
  2. Using a suitable suction device, remove the power steering fluid from the reservoir.
  3. Disconnect the power steering fluid return hose from the reservoir. Remove the clamp.
  4. Plug the power steering fluid reservoir inlet port.
  5. Attach an extension hose to the power steering return hose.
  6. Place the open end of the extension hose into a suitable container.
  7. Fill the power steering fluid reservoir with new fluid.
  8. Start the engine while simultaneously turning the steering wheel to lock and then immediately turn the ignition switch to the OFF position.
  9. Fill the power steering fluid reservoir with the approved power steering fluid.
  10. Repeat Steps 8 and 9 , turning the steering wheel in the opposite direction each time, until the fluid exiting the power steering fluid return hose is clean and clear of foreign material.
  11. Remove the extension hose from the power steering return hose.
  12. Remove the plug from the power steering fluid reservoir inlet port.
  13. Install the power steering return hose to the reservoir. Install the clamp.
  14. Fill the power steering system. For additional information, refer to «POWER STEERING SYSTEM FILLING»(/ford/cutaway-e350/2004-2007/remont/manual-power-steering/#steering-system-general-information) in this section.

SPECIAL TOOL(S) Vacuum Pump Kit 416-D002 (D95L-7559-A) or equivalent Evacuation Cap, Power Steering 211-265 or equivalent

Scheme 9

Scheme 9: Special Tool(s)
Scheme 9: Special Tool(s)

Scheme 10

Scheme 10
Scheme 10
ItemSpecification
MERCON® Multi-Purpose ATF Transmission Fluid XT-2-QDXMERCON®

MATERIAL SPECIFICATION

CAUTIONIf the air is not purged from the power steering system correctly, premature power steering pump failure can result. The condition can occur on pre-delivery vehicles with evidence of aerated fluid or on vehicles that have had steering component repairs.
  1. Remove the power steering pump reservoir cap. Check the fluid.
  2. Raise the front wheels off the floor. Refer to appropriate article for the procedure.
  3. Tightly insert the stopper of the vacuum pump into the reservoir.
  4. Start the engine.
  5. Install the vacuum pump, apply vacuum, and maintain the maximum vacuum of 68-85 kPa (20-25 in-Hg).
  6. If equipped with Hydro-Boost®, apply the brake pedal twice.
  7. Cycle the steering wheel fully from stop-to-stop 10 times.
  8. Stop the engine.
  9. Release the vacuum and remove the vacuum pump.
  10. Fill the reservoir. Use approved transmission fluid.
  11. Start the engine.
  12. Install the vacuum pump. Apply and maintain the maximum vacuum of 68-85 kPa (20-25 in-Hg).
  13. Cycle the steering wheel fully from stop-to-stop 10 times.
  14. Stop the engine, release the vacuum and remove the vacuum pump.
  15. Fill the reservoir as needed and install the reservoir cap.
  16. Visually inspect the power steering system for leaks.
  17. Fill the reservoir as needed and visually inspect the power steering system for leaks.
  18. Install the reservoir cap.

SPECIAL TOOL(S) Vacuum Pump Kit 416-D002 (D95L-7559-A) or equivalent Evacuation Cap, Power Steering 211-265 or equivalent Fill Adapter Manifold, Power Steering 211-327 or equivalent

Scheme 11

Scheme 11
Scheme 11
ItemSpecification
MERCON® Multi-Purpose ATF Transmission Fluid XT-2-QDXMERCON®

MATERIAL SPECIFICATION

  1. Remove the power steering pump reservoir cap.
  2. Tightly install the evacuation cap to the power steering pump reservoir.
  3. Install the hose from the fill adapter manifold tee to the evacuation cap on the power steering pump reservoir.
  4. Install the vacuum pump to the fill adapter manifold control valve.
  5. Install the hose to the opposite fill adapter manifold control valve and submerge the open end of the hose into a container of new power steering fluid.
  6. Close the fill adapter manifold control valve connected to the power steering fluid container.
  7. Open the fill adapter manifold control valve connected to the vacuum pump.
  8. Using the vacuum pump, apply 68-85 kPa (20-25 in-Hg) of vacuum to the power steering system.
  9. Observe the vacuum gauge for 30 seconds.
  10. If the vacuum gauge reading drops more than 3 kPa (0.88 in-Hg), correct any leaks in the power steering system or the filling tools before proceeding.
  11. Slowly open the fill adapter manifold control valve connected to the power steering fluid container until power steering fluid completely fills the hose.
  12. Close the fill adapter manifold control valve connected to the power steering fluid container.
  13. Using the vacuum pump, apply 68-85 kPa (20-25 in-Hg) of vacuum to the power steering system.
  14. Close the fill adapter manifold control valve connected to the vacuum pump.
  15. Slowly open the fill adapter manifold control valve connected to the power steering fluid container.
  16. When the power steering fluid has drained from the hose connected to the power steering fluid container, close the fill adapter manifold control valve connected to the power steering fluid container.
  17. Remove the tools from the vehicle.
  18. Install the power steering reservoir cap.
  19. Start the engine and turn the steering wheel from stop-to-stop.
  20. If equipped with Hydro-Boost®, apply the brake pedal twice.
  21. Turn the ignition switch to the OFF position.
  22. Remove the power steering reservoir cap and fill the reservoir.
  23. Install the power steering reservoir cap.

SPECIAL TOOL(S) Pitman Arm Puller T65P-3590-F

Scheme 12

Scheme 12
Scheme 12

Scheme 13

Scheme 13
Scheme 13

Scheme 14

Scheme 14
Scheme 14

Scheme 15

Scheme 15
Scheme 15

Scheme 16

Scheme 16
Scheme 16

Scheme 17

Scheme 17
Scheme 17

Scheme 18

Scheme 18
Scheme 18
  1. Turn the steering wheel from right lock to left lock at least once.
  2. Remove the driver air bag; for additional information, refer to «SUPPLEMENTAL RESTRAINT SYSTEM»(/ford/cutaway-e350/2004-2007/remont/airbag/#supplemental-restraint-system) .
  3. Raise and support the vehicle; for additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350/2004-2007/remont/hoistjack/#jacking-lifting) .
  4. Remove the castellated nut. Remove the cotter pin. Remove the castellated nut.
  5. Separate the steering sector shaft arm drag link. Use the Pitman Arm Puller to separate the steering sector shaft arm drag link.
  6. Lower and support the front of the vehicle; for additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350/2004-2007/remont/hoistjack/#jacking-lifting) .
  7. Attach a lb/in torque wrench to the bolt and measure the steering gear meshload from center.
  8. Adjust if not within specification.
  9. Adjust the sector shaft to proper rotating torque. Hold the sector shaft and loosen the lock nut. Adjust the sector shaft.
  10. Verify that the rotating torque is to specification. Reset if necessary.
  11. Tighten the lock nut. Hold the sector shaft. Tighten the lock nut.
  12. Install the steering sector shaft arm drag link, castellated nut and cotter pin.
  13. Lower the vehicle; for additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350/2004-2007/remont/hoistjack/#jacking-lifting) .
  14. Install the driver air bag; for additional information, refer to «SUPPLEMENTAL RESTRAINT SYSTEM»(/ford/cutaway-e350/2004-2007/remont/airbag/#supplemental-restraint-system) .