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Power Steering Ford Econoline I

Manual & Power Steering 69 illustrations ~6526 words

AIR BAG SYSTEM

CAUTIONRead the following safety precautions BEFORE servicing steering columns on vehicles equipped with air bag restraint system.

ALWAYS wear safety glasses when servicing a vehicle with an air bag and when handling an air bag.

Air bag system MUST be disabled BEFORE servicing ANY air bag component. See 1998 AIR BAG RESTRAINT SYSTEMS FORD MOTOR CO. DISABLING & ACTIVATING AIR BAG SYSTEM , 1999 ACCESSORIES & EQUIPMENT -- AIR BAG RESTRAINT SYSTEMS -- ECONOLINE DISABLING & ACTIVATING AIR BAG SYSTEM or 2000 AIR BAG RESTRAINT SYSTEMS -- ECONOLINE DISABLING & ACTIVATING AIR BAG SYSTEM

When handling an air bag module, ensure the bag and trim cover are pointed away from your body. This reduces the chance of injury in case of accidental air bag deployment. When placing the air bag module on a bench or any other surface, ALWAYS face the air bag and trim cover up, away from the surface. This reduces motion of the module if accidentally deployed.

Safety precautions must also be observed when handling a deployed air bag. After deployment the air bag surface may contain deposits of sodium hydroxide, a product of inflation gas generant combustion that irritates skin. ALWAYS wear gloves and safety glasses when handling an air bag. Wash hands with mild soap and water afterward.

NEVER probe connectors on an air bag module. Air bag may deploy causing personal injury.

DO NOT attempt to service an air bag module or contact assembly. To correct any system malfunctions, replace the complete assembly.

After any servicing, ensure the AIR BAG light does not indicate any faults.

Scheme 1

Scheme 1: DESCRIPTION & OPERATION
Scheme 1: DESCRIPTION & OPERATION

STEERING PUMP

The CIII power steering pump is a belt-driven, vane-type, power steering pump. (Scheme 2) It is mounted directly to the engine block by three bolts. The power steering pump is replaced as an assembly. An identification tag attached to the power steering pump indicates the model number and bar code. See these when pump replacement is required. The power steering pump uses a quick connect fitting for the power steering pressure hose. The power steering oil reservoir is mounted on the left hand side of the upper radiator support crossmember. (Scheme 3)

Scheme 2

Scheme 2: STEERING PUMP
Scheme 2: STEERING PUMP

Scheme 3

Scheme 3
Scheme 3

STEERING GEAR

The steering gear is a torsion-bar type hydraulic assisted system. It reduces road shock and vibration. It includes a rotary-style hydraulic valve. (Scheme 4) It uses a dot matrix ID mark on the gear housing between the valve housing and the sector shaft housing cover. (Scheme 5)

Scheme 4

Scheme 4: STEERING GEAR
Scheme 4: STEERING GEAR

STEERING GEAR IDENTIFICATION

CAUTIONAlways use the ID code when ordering service parts.

An identification tag may be attached to the valve housing. (Scheme 5)

Scheme 5

Scheme 5
Scheme 5

STEERING PUMP IDENTIFICATION

The pump identification code is located on a tag attached to the power steering pump. (Scheme 6)

Scheme 6

Scheme 6: STEERING PUMP IDENTIFICATION
Scheme 6: STEERING PUMP IDENTIFICATION

STEERING LINKAGE

The steering linkage components are shown in the following illustration. (Scheme 7)

Scheme 7

Scheme 7: STEERING LINKAGE
Scheme 7: STEERING LINKAGE

INSPECTION & VERIFICATION

CAUTIONDo not hold the steering wheel at the stops for an extended amount of time. Damage to the power steering pump will result.

Note. Make the following preliminary check Before repairing the steering system.

  1. Verify the customer concern by operating the steering system.
  2. Inspect the tires. Check tire pressure, verify that all tires are sized to specification, and/or inspect the tires for damage or uneven wear.
  3. Check drive belt and tension. See «1999 COOLING SYSTEM SPECIFICATIONS & DRIVE BELT ROUTING»(/ford/econoline/i-1985-2013/remont/accessory-drive-belts/#engine-cooling-system-specifications-drive-belt-routing) or «2000 SPECIFICATIONS & DRIVE BELT ROUTING -- TRUCKS»(ref-97626) .
  4. Fluid level check. Verify that the power steering fluid level is at the full (F) mark. Add Motorcraft MECRON® Multi-Purpose ATF XT-2-QDX or MECRON® equivalent.
  5. Verify that there is no air in the power steering system. Run the engine until it reaches normal operating temperature. turn the steering wheel to the left and right several times without hitting the stops. If any air bubbles are present, See «PURGING THE STEERING SYSTEM»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering__purging-the-steering-system) .
  6. With the ignition switch in the OFF position, wipe off the power steering pump, power steering pressure hose, power steering return hose, power steering fluid cooler and steering gear. With the engine running, turn the steering wheel from stop to stop several times. Do not hold steering wheel at stops. Check for leaks. Repair as necessary if any leaks are observed.
  7. Turning effort check. See «TURNING EFFORT»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering__turning-effort) under DIAGNOSIS & TESTING.
  8. Visually inspect for obvious signs of mechanical damage, check the following: Loose tie rod ends. Loose suspension components. Loose steering column shaft universal joints. Loose steering gear mounting bolts. Binding or misaligned steering column. Power steering pump. Bent or pinched power steering lines.
  9. If an obvious cause for an observed or reported malfunction is found, correct the cause (if possible) before proceeding to the next step.
  10. If the fault is not visually evident, determine the symptom to repair vehicle.

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, during very heavy or static parking maneuvers.

Possible Causes

  1. Seized lower steering column shaft U-joints.
  2. Damaged, fractured steering column bearing(s).
  3. Power steering pump.
  4. Suspension components.
  5. Steering gear internal leakage.

Actions To Repair

  1. Replace the lower steering column shaft U-joints. See «1998-99 STEERING COLUMNS -- TRUCKS -- EXCEPT STRIPPED»(/ford/econoline/i-1985-2013/remont/steering-column/#steering-column-except-stripped-chassis) or «2000 STEERING COLUMNS -- TRUCKS»(ref-94688) .
  2. Repair the steering column. See «1998-99 STEERING COLUMNS -- TRUCKS -- EXCEPT STRIPPED»(/ford/econoline/i-1985-2013/remont/steering-column/#steering-column-except-stripped-chassis) or «2000 STEERING COLUMNS -- TRUCKS»(ref-94688) .
  3. See «PUMP FLOW & PRESSURE TEST»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering__pump-flow-pressure-test) under DIAGNOSIS & TESTING.
  4. See «1998-99 SUSPENSION, FRONT -- 2WD VAN»(/ford/econoline/i-1985-2013/remont/suspension-front/#front-suspension-2wd) or «2000 SUSPENSION, FRONT -- 2WD ECONOLINE»(ref-97181) .
  5. See «PUMP FLOW & PRESSURE TEST»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering__pump-flow-pressure-test) under DIAGNOSIS & TESTING.

Possible Cause

  1. Power steering pump.

Action To Repair

  1. See «PUMP FLOW & PRESSURE TEST»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering__pump-flow-pressure-test) under DIAGNOSIS & TESTING.

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.

  1. Loose, worn or damaged steering linkages or tie rod end.
  2. Loose steering gear bolts.
  3. Damaged or worn steering gear.
  4. Loose, worn or damaged steering column bearing(s).
  5. Loose, worn or damaged lower steering column U-joints.
  1. See «STEERING LINKAGE»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering) under COMPONENT TESTS.
  2. Tighten the steering gear bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering__torque-specifications) .
  3. Repair the steering gear. See «POWER STEERING GEAR»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering) under REMOVAL & INSTALLATION.
  4. Replace any unserviceable steering column bearing(s). See «1998-99 STEERING COLUMNS -- TRUCKS -- EXCEPT STRIPPED»(/ford/econoline/i-1985-2013/remont/steering-column/#steering-column-except-stripped-chassis) or «2000 STEERING COLUMNS -- TRUCKS»(ref-94688) .
  5. Replace the lower steering column shaft. See «1998-99 STEERING COLUMNS -- TRUCKS -- EXCEPT STRIPPED»(/ford/econoline/i-1985-2013/remont/steering-column/#steering-column-except-stripped-chassis) or «2000 STEERING COLUMNS -- TRUCKS»(ref-94688) .

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.

  1. Unevenly loaded or overloaded vehicle.
  2. Loose or damaged steering gear mounting bolts.
  3. Loose lower steering column U-joint bolts.
  4. Loose, worn or damaged lower steering column shaft U-joints.
  5. Wheel alignment.
  6. Loose, worn or binding steering linkage(s) or tie rod end(s).
  7. Improper steering gear preload/meshload.
  8. Suspension components.
  1. Notify the customer of improper vehicle loading.
  2. Replace and/or tighten the steering gear mounting bolts. See «POWER STEERING GEAR»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering) under REMOVAL & INSTALLATION and/or «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering__torque-specifications) .
  3. Tighten the lower steering column U-joint bolts. See «1998-99 STEERING COLUMNS -- TRUCKS -- EXCEPT STRIPPED»(/ford/econoline/i-1985-2013/remont/steering-column/#steering-column-except-stripped-chassis) or «2000 STEERING COLUMNS -- TRUCKS»(ref-94688) .
  4. Replace the lower steering column shaft. See «1998-99 STEERING COLUMNS -- TRUCKS -- EXCEPT STRIPPED»(/ford/econoline/i-1985-2013/remont/steering-column/#steering-column-except-stripped-chassis) or «2000 STEERING COLUMNS -- TRUCKS»(ref-94688) .
  5. See «1998-99 SPECIFICATIONS & PROCEDURES -- TRUCKS»(/ford/econoline/i-1985-2013/remont/wheel-alignment/#wheel-alignment-specifications-adjustment-procedures-specifications-procedures-trucks) or «2000 SPECIFICATIONS & PROCEDURES -- TRUCKS»(ref-97260) .
  6. See «STEERING LINKAGE»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering) under COMPONENT TESTS.
  7. See «STEERING GEAR MESHLOAD ADJUSTMENT»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering__steering-gear-meshload-adjustment) under ADJUSTMENTS & INSPECTION.
  8. See «1998-99 SUSPENSION, FRONT -- 2WD VAN»(/ford/econoline/i-1985-2013/remont/suspension-front/#front-suspension-2wd) or «2000 SUSPENSION, FRONT -- 2WD ECONOLINE»(ref-97181) .

DRIFT/PULL

Pull is 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 hands off the steering wheel. A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead path and require constant steering input in the opposite direction to counteract the effect. Drift/pull may be induced by conditions external to the vehicle (i.e., wind, road camber

  1. Unevenly loaded or overloaded vehicle.
  2. Wheel Alignment.
  3. Loose, worn or binding steering linkage(s) or tie rod(s).
  4. Suspension components.
  5. The steering gear valve effort out of balance.
  6. Check the brake system for proper operation.
  7. Improper frame/underbody alignment.
  1. Notify the customer of improper vehicle loading.
  2. See «1998-99 SPECIFICATIONS & PROCEDURES -- TRUCKS»(/ford/econoline/i-1985-2013/remont/wheel-alignment/#wheel-alignment-specifications-adjustment-procedures-specifications-procedures-trucks) or «2000 SPECIFICATIONS & PROCEDURES -- TRUCKS»(ref-97260) under FRONT SUSPENSION.
  3. See «STEERING LINKAGE»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering) under COMPONENT TESTS.
  4. See «1998-99 SUSPENSION, FRONT -- 2WD VAN»(/ford/econoline/i-1985-2013/remont/suspension-front/#front-suspension-2wd) or «2000 SUSPENSION, FRONT -- 2WD ECONOLINE»(ref-97181) .
  5. See «STEERING GEAR VALVE»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering__steering-gear-valve) under DIAGNOSIS & TESTING.
  6. See «1998-99 DISC & DRUM -- TRUCKS -- EXCEPT VILLAGER»(/ford/econoline/i-1985-2013/remont/mechanical-hydraulic/#disc-brake-system-drum-brake-system) or «2000 DISC & DRUM -- TRUCKS -- EXCEPT VILLAGER»(ref-96447) .
  7. Correct as required.

FEEDBACK

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

  1. Loose, worn or damaged steering linkage(s) or tie rod end(s).
  2. Loose or damaged steering gear mounting bolts.
  3. Loose lower steering column shaft U-joint bolts.
  4. Loose suspension bushings, fasteners or ball joints.
  5. Worn or damaged steering column bearing(s).
  1. See «STEERING LINKAGE»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering) under COMPONENT TESTS.
  2. See «POWER STEERING GEAR»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering) under REMOVAL & INSTALLATION and/or «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering__torque-specifications) .
  3. Tighten the lower steering column shaft U-joint bolts to specification. «1998-99 STEERING COLUMNS -- TRUCKS -- EXCEPT STRIPPED»(/ford/econoline/i-1985-2013/remont/steering-column/#steering-column-except-stripped-chassis) or «2000 STEERING COLUMNS -- TRUCKS»(ref-94688) .
  4. Replace as necessary. See «1998-99 SUSPENSION, FRONT -- 2WD VAN»(/ford/econoline/i-1985-2013/remont/suspension-front/#front-suspension-2wd) or «2000 SUSPENSION, FRONT -- 2WD ECONOLINE»(ref-97181) .
  5. Replace any unserviceable steering column bearing(s). See «1998-99 STEERING COLUMNS -- TRUCKS -- EXCEPT STRIPPED»(/ford/econoline/i-1985-2013/remont/steering-column/#steering-column-except-stripped-chassis) or «2000 STEERING COLUMNS -- TRUCKS»(ref-94688) .

STICKY STEERING, POOR TURNABILITY

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

  1. Binding lower steering column shaft U-joints.
  2. Loose, worn or binding steering linkage(s) or tie rod end(s).
  3. Check the steering gear for evidence of binding or damage.
  4. Suspension Components.
  5. Wheel alignment.
  6. Binding steering column bearing(s).
  1. Replace the lower steering column shaft. See «1998-99 STEERING COLUMNS -- TRUCKS -- EXCEPT STRIPPED»(/ford/econoline/i-1985-2013/remont/steering-column/#steering-column-except-stripped-chassis) or «2000 STEERING COLUMNS -- TRUCKS»(ref-94688) .
  2. See «STEERING LINKAGE»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering) under COMPONENT TESTS.
  3. Repair the steering gear. See «POWER STEERING GEAR»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering) under REMOVAL & INSTALLATION.
  4. See «1998-99 SUSPENSION, FRONT -- 2WD VAN»(/ford/econoline/i-1985-2013/remont/suspension-front/#front-suspension-2wd) or «2000 SUSPENSION, FRONT -- 2WD ECONOLINE»(ref-97181) for suspension system diagnosis and testing.
  5. See «1998-99 SPECIFICATIONS & PROCEDURES -- TRUCKS»(/ford/econoline/i-1985-2013/remont/wheel-alignment/#wheel-alignment-specifications-adjustment-procedures-specifications-procedures-trucks) or «2000 SPECIFICATIONS & PROCEDURES -- TRUCKS»(ref-97260) under FRONT SUSPENSION.
  6. Replace the steering column bearings. See «1998-99 STEERING COLUMNS -- TRUCKS -- EXCEPT STRIPPED»(/ford/econoline/i-1985-2013/remont/steering-column/#steering-column-except-stripped-chassis) or «2000 STEERING COLUMNS -- TRUCKS»(ref-94688) .

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

  1. Loose, worn or damaged steering linkage(s) or tie rod end(s).
  2. Suspension system components.
  1. See «STEERING LINKAGE»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering) under COMPONENT TESTS.
  2. See «1998-99 SUSPENSION, FRONT -- 2WD VAN»(/ford/econoline/i-1985-2013/remont/suspension-front/#front-suspension-2wd) or «2000 SUSPENSION, FRONT -- 2WD ECONOLINE»(ref-97181) for suspension system diagnosis and testing.

DIAGNOSIS & TESTING

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

TURNING EFFORT

  1. Park the vehicle on dry concrete and set the parking brake.
  2. Insert a thermometer into the power steering oil reserve.
  3. Idle the engine for two to three minutes. Turn the steering wheel from stop to stop several times to warm the fluid to 122-140°F (50-60°C).
  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, see «GENERAL SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering__general-specifications) . Is the pull measurement OK? If yes, the system is good. If no, See «TROUBLE SHOOTING»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering) .

PUMP FLOW & PRESSURE TEST

WARNINGDo not touch the flowmeter during the test procedure, or severe burns and serious injury may occur.
  1. Install the Power Steering Analyzer (014-00207) or equivalent at the high pressure port of the power steering pump. Make sure the power steering analyzer gate valve is fully open. On some vehicles, the power steering pump high pressure port is inaccessible and the power steering analyzer should then be installed either at the steering gear or at a point in the high pressure line between the power steering pump and the steering gear.
  2. Place a dial thermometer in the power steering oil reservoir.
  3. Check the power steering fluid level. If necessary, add power steering fluid. Use Motorcraft MERCON® Multi-Purpose ATF XT-2-QDX or MERCON® equivalent.
  4. Install the digital tachometer.
  5. Start the engine. Place the transmission in NEUTRAL. Set the parking brake. Raise the power steering fluid temperature to 165-175°F (74-80°C) by rotating the steering wheel fully to the left and right several times.
  6. Set the engine idle speed to 1500 RPM. Record the flow rate and pressure readings. If the flow rate is below the flow rate specification, the power steering pump may require repair. Continue with the test procedure. If the pressure reading is above the maximum pressure specification, then check 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, the replace the power steering pump. See «GENERAL SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering) .
  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 replace the power steering pump.
  9. Set engine speed at 1500 RPM. Record the flow rate. If the flow rate varies more than 1 gallon/minute (3.785 liters/minute) from the initial flow rate reading, then replace the 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 0.5 gallons/minute (1.9 liters/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. Repair or replace the steering gear as necessary. See «POWER STEERING GEAR»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering) under REMOVAL & INSTALLATION.
  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 servicing the steering gear. See «STEERING LINKAGE»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering) under COMPONENT TESTS.

STEERING GEAR VALVE

  1. With the vehicle in motion, place the transmission in the NEUTRAL position and turn the engine OFF. If the vehicle does not pull with the engine OFF, repair or replace the steering gear. See «POWER STEERING GEAR»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering) under REMOVAL & INSTALLATION.
  2. If the vehicle pulls with the engine OFF, cross-switch the front wheels. If the vehicle pulls to the opposite side, cross-switch the front and rear wheel s on the same side.
  3. If the vehicle pull direction does not change, check the front suspension components, wheel alignment and frame alignment.

Note. The steering linkage ball studs are spring loaded and will have a small amount of up and down movement if the spring is compressed. Do not use a prying device or adjustable pliers to check the steering linkage components.

  1. Turn the steering wheel to the straight-ahead position and turn the ignition switch to the OFF position.
  2. Raise and support the vehicle.
  3. Check and, if necessary, adjust the front wheel bearings. See «1998-99 SUSPENSION, FRONT -- 2WD VAN»(/ford/econoline/i-1985-2013/remont/suspension-front/#front-suspension-2wd) or «2000 SUSPENSION, FRONT -- 2WD ECONOLINE»(ref-97181) .
  4. Install the tire and wheel Run-Out Gauge Set (164-R1099 or equivalent) to the steering linkage component being tested.
  5. Have an assistant grasp the tire and move the steering linkage from side-to-side. Observe and record the movement measured with the dial indicator.
  6. If the movement exceeds 0.04 in (1mm) install a new steering linkage component.

LUBRICATION

WARNINGDo not mix oil types. Any mixture or any unapproved oil could lead to seal deterioration and leaks. A leak could ultimately cause loss of fluid, which could result in a loss of power steering assist.

FILLING THE STEERING SYSTEM

  1. Fill the reservoir. Use Motorcraft MERCON® Multi-Purpose (ATF) XT-2-QDX or MERCON® equivalent. (Scheme 14)
  2. Remove the Powertrain Control Module (PCM) relay to disable the vehicle. (Scheme 10)
  3. Raise the front wheels off the ground.
  4. Turn the steering wheel from stop-to-stop while cranking the engine.
  5. Lower the vehicle.
  6. Fill the reservoir, be sure not to overfill. Use Motorcraft MERCON® Multi-Purpose (ATF) XT-2-QDX or MERCON® equivalent.
  7. Install the powertrain control module (PCM) relay. (Scheme 10)
  8. Clear the diagnostic trouble codes (DTCs). For additional information, See appropriate SELF-DIAGNOSTIC article under ENGINE PERFORMANCE. Run vehicle and check the system for leaks.

Final Fill

  1. Adjust the fluid level in the power steering fluid reservoir to correct the level. There will be a slight drop in the level when the engine is first started and the steering wheel is cycled.
  2. Operate the engine at an idle for 15 minutes, then inspect for leaks. It will not be necessary to purge the system unless there is evidence of air in the power steering pump.

FLUSHING THE STEERING SYSTEM

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.

Scheme 8

Scheme 8
Scheme 8

Scheme 9

Scheme 9
Scheme 9

Scheme 10

Scheme 10
Scheme 10

Scheme 11

Scheme 11
Scheme 11
  1. Remove the Powertrain Control Module (PCM) relay to disable the vehicle. (Scheme 10) NOTE: PCM relay is located in engine compartment fuse box. Engine compartment fuse box is in left front of engine compartment.
  2. Remove the reservoir from the reservoir bracket. (Scheme 11)
  3. Remove the reservoir bracket. (Scheme 12)
  4. Disconnect the power steering return hose (Scheme 13) Plug the reservoir.
  5. Attach an extension hose between the power steering return hose and an empty container.
  6. Raise the front wheels off the floor.
  7. Fill the reservoir. (Scheme 14) Use Motorcraft MECRON® Multi-Purpose ATF XT-2-QDX or equivalent MECRON® fluid.
  8. Turn the steering wheel from stop-to-stop while cranking the engine until the fluid exiting the power steering return hose is clear of all contamination and debris. Add Motorcraft MERCON® Multi-Purpose ATF XT-2-QDX or MERCON® equivalent as needed.
  9. Lower the vehicle.
  10. Disconnect the extension hose from the power steering return hose. Remove the plug. Attach the power steering return hose to the reservoir. (Scheme 13)
  11. Install the reservoir bracket. (Scheme 12)
  12. Install the reservoir to the bracket. (Scheme 11)
  13. Fill the reservoir. Be sure not to overfill. Use Motorcraft MERCON® Multi-Purpose ATF XT-2-QDX or equivalent MERCON® fluid.
  14. Install the Powertrain Control Module (PCM) relay. (Scheme 10)
  15. Start the engine and turn the steering wheel from stop-to-stop.
  16. Check the power steering fluid level. (Scheme 14) Use Motorcraft MERCON® Multi-Purpose ATF XT-2-QDX or equivalent MERCON® fluid.

Scheme 12

Scheme 12
Scheme 12

PURGING THE STEERING SYSTEM

CAUTIONIf the air is not purged from the power steering system correctly, premature power steering pump failure could result. This condition can occur on pre-delivery vehicles with evidence of aerated fluid on vehicles that have had steering component repairs.

Note. A whine heard from the power steering pump may be caused by air in the system. The power steering purge procedure must be performed prior to any component repair for which power steering noise complaints are accompanied by evidence of aerated fluid.

  1. Remove the reservoir cap and check the fluid. Use Motorcraft MERCON® Multi-Purpose ATF XT-2-QDX or MERCON® equivalent. (Scheme 14)
  2. Tightly insert the stopper of the vacuum pump into the reservoir. (Scheme 15)
  3. Start the vehicle.
  4. Apply maximum vacuum and maintain it for a minimum of three minutes with the engine speed set at idle. (Scheme 16)
  5. Release the vacuum and remove the vacuum pump.
  6. Fill the reservoir. Be sure not to over fill. Use Motorcraft MERCON® Multi-Purpose ATF XT-2-QDX or MERCON® equivalent. (Scheme 14)
  7. Install the vacuum pump. Apply and maintain maximum vacuum. (Scheme 16)
  8. Cycle the steering wheel fully to the left and right every 30 seconds for approximately five minutes.
  9. Stop the engine, release the vacuum, and remove the vacuum pump.
  10. Install the reservoir cap. (Scheme 14)
  11. Check for fluid leaks at all of the connections. If the power steering fluid shows signs of air, repeat this procedure.

Scheme 13

Scheme 13
Scheme 13

Scheme 14

Scheme 14
Scheme 14

STEERING GEAR MESHLOAD ADJUSTMENT

Note. The engine should not be running during meshload adjustment.

Scheme 15

Scheme 15: STEERING GEAR MESHLOAD ADJUSTMENT
Scheme 15: STEERING GEAR MESHLOAD ADJUSTMENT

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 air bag. See 1998 AIR BAG RESTRAINT SYSTEMS FORD MOTOR CO. «DISABLING & ACTIVATING AIR BAG SYSTEM»(ref-97838-S27328137002001051100000),1999 ACCESSORIES & EQUIPMENT -- AIR BAG RESTRAINT SYSTEMS -- ECONOLINE «DISABLING & ACTIVATING AIR BAG SYSTEM»(/ford/econoline/i-1985-2013/remont/airbag/#air-bag-restraint-system__disabling-activating-air-bag-system) or 2000 AIR BAG RESTRAINT SYSTEMS -- ECONOLINE «DISABLING & ACTIVATING AIR BAG SYSTEM»(ref-96540-S24737166292001041800000).
  3. Raise and support the vehicle.
  4. Remove the cotter pin and the castellated nut. (Scheme 17)
  5. Using a Pitman Arm Puller, separate the steering sector shaft arm drag link. (Scheme 18)
  6. Lower and support the front of the vehicle.
  7. Attach an INCH lb. torque wrench to the bolt. Measure the steering gear meshload from center. (Scheme 19)
  8. Adjust if less than 13 INCH lbs. (1 N.m). (Scheme 19)
  9. Hold the sector shaft and loosen the lock nut, then adjust the sector shaft to rotating torque. (Scheme 20)
  10. Verify that the rotating torque is 12-16 INCH lbs. (1.4-1.8 N.m). Reset if necessary. (Scheme 19)
  11. Hold the sector shaft and tighten the lock nut to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering__torque-specifications).
  12. Install the steering sector shaft arm drag link, castellated nut and cotter pin. (Scheme 17) Tighten the castellated nut to specification, See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering__torque-specifications).
  13. Lower the vehicle.
  14. Install the drivers side air bag. See 1998 AIR BAG RESTRAINT SYSTEMS FORD MOTOR CO. «DISABLING & ACTIVATING AIR BAG SYSTEM»(ref-97838-S27328137002001051100000),1999 ACCESSORIES & EQUIPMENT -- AIR BAG RESTRAINT SYSTEMS -- ECONOLINE «DISABLING & ACTIVATING AIR BAG SYSTEM»(/ford/econoline/i-1985-2013/remont/airbag/#air-bag-restraint-system__disabling-activating-air-bag-system) or 2000 AIR BAG RESTRAINT SYSTEMS -- ECONOLINE «DISABLING & ACTIVATING AIR BAG SYSTEM»(ref-96540-S24737166292001041800000).

ADJUSTING SLEEVE

Note. Replace the ball stud if loose in the steering control ball stud socket or the tie rod end is bent. Replace the front suspension steering ball stud dust seal if any nicks, cuts or tears are present. Do not attempt to straighten a bent tie rod end.

Removal

  1. Raise the vehicle on a hoist, with the wheels in the straight-ahead position.
  2. Remove the cotter pin, then the tie rod end castle nut. (Scheme 26)
  3. Using the Pitman Arm Puller, remove the ball stud from the front wheel spindle. see scheme 28
  4. Loosen the nuts on the tie rod adjusting sleeve. Count the number of turns while removing the tie rod end from the tie rod adjusting sleeve. see scheme 29
  5. Remove the tie rod adjusting sleeve. Count the number of turns required to remove the tie rod adjusting sleeve clamp.

Installation

Note. The two bolts and nuts on the tie rod adjusting sleeve clamp for the tie rod end must be positioned within a limit of 45 degrees (±). The threaded ends of the bolts on the left tie rod end point toward the front of the vehicle. The threaded ends on the right tie rod end face rearward.

  1. Follow the removal procedure in reverse order. Make sure the adjuster clamps are in the correct position.
  2. Tighten the tie rod adjusting sleeve to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering__torque-specifications). see scheme 29
  3. Install the stud in the front wheel spindle, then tighten the castle nut to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering__torque-specifications). see scheme 28
  4. Install a new cotter pin.
  5. Check front toe-in. See «1998-99 SPECIFICATIONS & PROCEDURES -- TRUCKS»(/ford/econoline/i-1985-2013/remont/wheel-alignment/#wheel-alignment-specifications-adjustment-procedures-specifications-procedures-trucks) or «2000 SPECIFICATIONS & PROCEDURES -- TRUCKS»(ref-97260).
  6. Check for clear vision.

Scheme 19

Scheme 19: Removal
Scheme 19: Removal
  1. Remove the nut retaining the damper to the bracket on the steering linkage. (Scheme 21)
  2. Remove the nut and bolt retaining the damper to the right hand damper bracket. (Scheme 22)
  3. Remove the damper from the mounting brackets. (Scheme 23)

Note. When installing a new steering linkage bracket, make sure the bracket is properly positioned on the steering sector shaft arm drag link before tightening the U-bolt retaining nuts.

  1. Install the damper into the mounting brackets.
  2. Install the damper bolt and nut retaining the damper to the right hand bracket. (Scheme 22) Tighten the bolt to specification, See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering__torque-specifications).
  3. Install the nut retaining the damper to the steering linkage left hand bracket. (Scheme 21) Tighten the bolt to specification, See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering__torque-specifications).
  4. Rotate the steering wheel from stop to stop. Verify that the steering linkage damper is not bottoming out and that the steering linkage reaches its full travel when the steering wheel is turned from stop to stop.

(Scheme 1)for the hose routing and retention points.

  1. When connecting a fitting with a seal ring, the ring must be replaced. The Seal Replacer is used to install the return line connector seal and the pressure line connector seal. (Scheme 43)
  2. Fill, purge and leak check the system. See «FILLING THE STEERING SYSTEM»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering__filling-the-steering-system), «PURGING THE STEERING SYSTEM»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering__purging-the-steering-system).

INNER TIE ROD END

Note. Replace the steering tie rod if the ball stud is loose in the steering control ball stud socket or the rod is bent. Replace the front suspension steering ball stud dust seal if any nicks, cuts or tears are present. Do not attempt to straighten a bent rod.

Scheme 20

Scheme 20: Removal
Scheme 20: Removal

Scheme 21

Scheme 21
Scheme 21

Scheme 22

Scheme 22
Scheme 22
  1. Position the wheels in the straight-ahead position. Raise and support the vehicle.
  2. Remove the cotter pin then the castellated nut. (Scheme 24)
  3. Using the Pitman Arm Puller, remove the ball stud from the steering sector shaft arm drag link. see scheme 25
  4. Loosen the bolts on the tie rod adjusting sleeve clamp. Count and record the number of turns required to remove the tie rod end from the tie rod adjusting sleeve clamp. (Scheme 25)

Note. The two bolts and nuts on the tie rod adjusting sleeve clamp for the tie rod end must be positioned within a limit of 45 degrees (±). The threaded ends of the bolts on the left tie rod end point toward the front of the vehicle. The threaded ends of the bolts on the right tie rod end face rearward.

  1. Turn the tie rod end into the tie rod adjusting sleeve clamp with the same number of turns as required for removal. (Scheme 25) Tighten the tie rod end adjusting sleeve clamp bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering__torque-specifications).
  2. Install the castle nut and a new cotter pin. (Scheme 24)
  3. Check toe-in. See «1998-99 SPECIFICATIONS & PROCEDURES -- TRUCKS»(/ford/econoline/i-1985-2013/remont/wheel-alignment/#wheel-alignment-specifications-adjustment-procedures-specifications-procedures-trucks) or «2000 SPECIFICATIONS & PROCEDURES -- TRUCKS»(ref-97260).

Scheme 23

Scheme 23: Removal
Scheme 23: Removal

Scheme 24

Scheme 24
Scheme 24
  1. Raise and support the vehicle.
  2. Remove the cotter pin then the tie rod end castellated nut. (Scheme 26)
  3. Using a Pitman Arm Puller, remove the tie rod end ball stud from the front wheel spindle. see scheme 28
  4. Loosen the bolts on the tie rod adjusting sleeve clamp. Count the number of turns required to remove the tie rod end from the tie rod adjusting sleeve clamp. see scheme 29
  1. Turn the tie rod end into the tie rod adjusting sleeve clamp approximately the same number of turns used to remove old tie rod end. This will provide an approximate toe-in setting.
  2. Tighten the tie rod adjusting sleeve clamp to specification, See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering__torque-specifications). see scheme 29
  3. Install the ball stud in the front wheel spindle, then tighten the castle nut to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering__torque-specifications). see scheme 28
  4. Install a new cotter pin.
  5. Check toe-in. See «1998-99 SPECIFICATIONS & PROCEDURES -- TRUCKS»(/ford/econoline/i-1985-2013/remont/wheel-alignment/#wheel-alignment-specifications-adjustment-procedures-specifications-procedures-trucks) or «2000 SPECIFICATIONS & PROCEDURES -- TRUCKS»(ref-97260).

Scheme 25

Scheme 25: Removal & Installation
Scheme 25: Removal & Installation

Scheme 26

Scheme 26
Scheme 26

Scheme 27

Scheme 27
Scheme 27

Scheme 28

Scheme 28
Scheme 28

Scheme 29

Scheme 29
Scheme 29
  1. Remove the pinch bolt. (Scheme 27)
  2. Slide the intermediate shaft off the steering gear input shaft. (Scheme 28)
  3. Turn the ignition key to the locked position.
  4. Disconnect the power steering lines at the steering gear. (Scheme 29)
  5. Raise and support the vehicle.
  6. Remove the cotter pin, then the steering sector shaft arm drag link castellated nut. (Scheme 30)
  7. Use the Pitman Arm Puller to separate the drag link. (Scheme 31)
  8. Remove the bolts and the steering gear. (Scheme 32)
  9. Secure the steering gear in a bench vise. Remove the steering gear sector shaft arm nut and lockwasher. (Scheme 33)
  10. Use the Pitman Arm Puller to remove the steering gear sector shaft arm. (Scheme 34)
  11. To install, reverse the removal procedure. Tighten the castellated nut, and steering gear bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering__torque-specifications).
  12. Fill, purge and leak check the system. See «FILLING THE STEERING SYSTEM»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering__filling-the-steering-system) or «PURGING THE STEERING SYSTEM»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering__purging-the-steering-system).

Scheme 30

Scheme 30: Removal & Installation
Scheme 30: Removal & Installation
  1. Raise the vehicle.
  2. Remove the return hose from the power steering pump and drain the power steering oil reservoir. (Scheme 35)
  3. Lower the vehicle.
  4. Lift the reservoir out of the reservoir bracket.
  5. Compress clamps and disconnect the power steering return hose and the power steering reservoir pump hose.
  6. Remove the power steering pump reservoir. (Scheme 12)
  7. To install, reverse the removal procedure.
  8. Fill, purge and leak check the system. See «FILLING THE STEERING SYSTEM»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering__filling-the-steering-system) or «PURGING THE STEERING SYSTEM»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering__purging-the-steering-system).

SECTOR SHAFT ARM DRAG LINK

Note. Replace the steering sector shaft arm drag link or tie rod end if the following conditions are present: Ball stud is excessively loose in the socket of the tie rod end. Steering sector shaft arm drag link is bent. Taper for the tie rod end is loose. Replace the front suspension steering ball stud dust seal if any nicks, cuts or tears are present.

CAUTIONDo not attempt to straighten a steering sector shaft arm drag link or tie rod end.

Scheme 31

Scheme 31: Removal
Scheme 31: Removal
  1. Remove the cotter pins and discard, then remove the castellated nuts. (Scheme 36)
  2. Remove the outer tie rod end from the right hand steering knuckle. See «OUTER TIE ROD END»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering).
  3. Remove the left hand inner tie rod end from the steering sector shaft arm drag link. See «INNER TIE ROD END»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering__inner-tie-rod-end).
  4. Remove and discard the cotter pin, then remove the steering sector shaft arm drag link castellated nut. (Scheme 30)
  5. Using the Pitman Arm Puller, separate the steering sector shaft arm drag link. (Scheme 31)
  6. Remove the tie rod adjusting sleeve from the drag link. Count the number of turns required to remove the tie rod adjusting sleeve.
  1. Follow the removal procedure in reverse order. Install new cotter pins.
  2. Tighten the castellated nuts and the tie rod adjusting sleeve bolts to specification, See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering__torque-specifications) .
  3. Check toe-in, See «1998-99 SPECIFICATIONS & PROCEDURES -- TRUCKS»(/ford/econoline/i-1985-2013/remont/wheel-alignment/#wheel-alignment-specifications-adjustment-procedures-specifications-procedures-trucks) or «2000 SPECIFICATIONS & PROCEDURES -- TRUCKS»(ref-97260) .
  4. Check for clear vision.

SECTOR SHAFT ARM

Note. Replace the steering gear sector shaft arm if it is bent. If the steering gear sector shaft arm is bent, also check the drag link, steering tie rod, tie rod adjustment sleeves and tie rod ball studs for signs of damage. Replace damaged steering linkage as required. Do not attempt to straighten the steering gear sector shaft arm or any other steering linkage components.

Scheme 32

Scheme 32: Removal & Installation
Scheme 32: Removal & Installation
  1. Raise and support the vehicle.
  2. Remove the cotter pin, then remove the steering sector shaft arm drag link castellated nut. (Scheme 30)
  3. Using the Pitman Arm Puller, separate the steering sector shaft arm drag link. (Scheme 31)
  4. Scribe alignment marks on the steering gear sector shaft and steering gear sector shaft arm. (Scheme 37)
  5. Remove the sector shaft arm nut and washer. (Scheme 37)
  6. Using the Pitman Arm Puller, remove the steering gear sector shaft arm. (Scheme 38)
  7. To install, reverse the removal procedure. Tighten the steering sector shaft arm drag link castellated nut to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering__torque-specifications).

Scheme 33

Scheme 33
Scheme 33

Scheme 34

Scheme 34: Removal & Installation
Scheme 34: Removal & Installation

Scheme 35

Scheme 35
Scheme 35
  1. Remove the transmission fluid cooler. See «TRANSMISSION FLUID COOLER»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering).
  2. Disconnect the hoses at the fluid cooler. (Scheme 39)
  3. Remove the two power steering cooler bolts and remove the power steering cooler. (Scheme 40)
  4. To install, reverse the removal procedure. Tighten the power steering cooler bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering__torque-specifications).
  5. Fill, purge and leak check the system. See «FILLING THE STEERING SYSTEM»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering__filling-the-steering-system) or «PURGING THE STEERING SYSTEM»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering__purging-the-steering-system).

Scheme 36

Scheme 36: Removal & Installation
Scheme 36: Removal & Installation

Scheme 37

Scheme 37
Scheme 37

Scheme 38

Scheme 38
Scheme 38
  1. Remove the power steering pump pulley. See «STEERING PUMP PULLEY»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering).
  2. Disconnect the power steering reservoir pump hose and pressure line from the power steering pump. (Scheme 41) Drain the power steering oil reservoir.
  3. Remove the three bolts and the pump. (Scheme 42)
  4. To install, reverse the removal procedure. Install a new power steering seal on the power steering pressure fitting by stretching the seal over the seal replacer until it is large enough to slip over the threads of the fitting. (Scheme 43)
  5. Install the steering pump pulley. See «STEERING PUMP PULLEY»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering).
  6. Fill, purge and leak check the system. See «FILLING THE STEERING SYSTEM»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering__filling-the-steering-system) or «PURGING THE STEERING SYSTEM»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering__purging-the-steering-system).

Scheme 39

Scheme 39: Removal
Scheme 39: Removal
  1. Remove the power steering pump. See «STEERING PUMP»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering).
  2. Hold the Steering Pump Pulley Remover and rotate the forcing bolt to remove the power steering pump pulley. (Scheme 44)

Scheme 40

Scheme 40: Installation
Scheme 40: Installation
  1. Thread the forcing bolt into the power steering pump and turn the Steering Pump Pulley Replacer to install the pump pulley. (Scheme 45)
  2. Install the power steering pump. See «STEERING PUMP»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering).
  1. Remove the air cleaner assembly and the mounting bracket. Remove the front radiator air deflector. Remove the radiator grille opening panel reinforcement.
  2. With a suitable drain pan properly positioned, disconnect the fluid cooler hoses at the transmission fluid cooler (7A095). Remove the transmission fluid cooler.

Follow the removal procedure in reverse order. Fill the transmission to the specified level with Motorcraft MERCON® Multi-Purpose Automatic Transmission Fluid XT-2-QDX or MERCON® equivalent.

Note. The steering gear input shaft and seals cannot be repaired or replaced separately. Gear replacement may be necessary.

Scheme 41

Scheme 41: Disassembly
Scheme 41: Disassembly

Scheme 42

Scheme 42
Scheme 42

Scheme 43

Scheme 43
Scheme 43

Scheme 44

Scheme 44
Scheme 44

Scheme 45

Scheme 45
Scheme 45

Scheme 46

Scheme 46
Scheme 46

Scheme 47

Scheme 47
Scheme 47

Scheme 48

Scheme 48
Scheme 48

Scheme 49

Scheme 49
Scheme 49

Scheme 50

Scheme 50
Scheme 50

Scheme 51

Scheme 51
Scheme 51

Scheme 52

Scheme 52
Scheme 52

Scheme 53

Scheme 53
Scheme 53

Scheme 54

Scheme 54
Scheme 54

Scheme 55

Scheme 55
Scheme 55

Scheme 56

Scheme 56
Scheme 56

Scheme 57

Scheme 57
Scheme 57

Scheme 58

Scheme 58
Scheme 58

Scheme 59

Scheme 59
Scheme 59
  1. Secure the steering gear in a vise with the indexing flat pointed down. Use protective caps on the vise jaws. (Scheme 46)
  2. Rotate the power steering gear input shaft and control from stop to stop and then center the gear. (Scheme 47)
  3. Remove the steering gear sector shaft housing cover bolts. (Scheme 48)
  4. Tap on the lower end of the steering gear sector shaft. (Scheme 49)
  5. Remove the steering gear sector shaft. (Scheme 50)
  6. Remove the lock nut from the steering gear sector shaft adjustment screw. (Scheme 51)
  7. Hold the steering gear sector shaft, and turn the housing cover counterclockwise to remove. (Scheme 52)
  8. Remove the valve housing bolts and the identification tag. (Scheme 53)
  9. Remove the valve housing and piston assembly. (Scheme 54)
  10. Remove and discard the gasket. (Scheme 55)
  11. Remove the bolts, the steering gear ball return guide clamp, and the steering gear ball return guide. Rotate the piston over a container to collect the 28 steering gear worm balls. (Scheme 56)
  12. Remove the input shaft valve and housing assembly from the piston. (Scheme 57)
  13. Remove and discard the seal. (Scheme 58)
  14. Install the valve housing in the Bench Mounted Holding Fixture and loosen the setscrew. (Scheme 59)
  15. Use Adjuster and Locknut Wrench to remove the input shaft race nut. (Scheme 60)
  16. Remove the power steering gear input shaft and control from the valve housing. (Scheme 61)
  17. Rotate the valve housing with the Bench Mounted Holding Fixture.
  18. Use the Puller to remove the power steering gear input shaft seal dust seal. (Scheme 62)
  19. Remove the input shaft snap ring. (Scheme 63)
  20. Rotate the valve housing with the Bench Mounted Holding Fixture, and use the Input Shaft Bearing/Seal Tool to remove the bearing and power steering input shaft seal. (Scheme 64)
  21. Remove the valve housing from the Bench Mounted Holding Fixture.
  22. Install the steering gear housing in the Bench Mounted Holding Fixture and remove the steering gear sector shaft dust seal from the sector shaft seal bore. (Scheme 65)
  23. Remove the snap ring, then the spacer. (Scheme 66)
  24. Use the Puller to remove the sector shaft seal. (Scheme 67)

Scheme 60

Scheme 60: Reassembly
Scheme 60: Reassembly

Scheme 61

Scheme 61
Scheme 61

Scheme 62

Scheme 62
Scheme 62

Scheme 63

Scheme 63
Scheme 63

Scheme 64

Scheme 64
Scheme 64

Scheme 65

Scheme 65
Scheme 65

Scheme 66

Scheme 66
Scheme 66

Scheme 67

Scheme 67
Scheme 67

Scheme 68

Scheme 68
Scheme 68

Scheme 69

Scheme 69
Scheme 69
  1. Lubricate the sector shaft seal bore. (Scheme 65) Use Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A.
  2. Use the Sector Shaft Seal Replacer to install the sector shaft seal. (Scheme 68) Lubricate the sector shaft seal, using Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A.
  3. Install the spacer. (Scheme 66)
  4. Install the snap ring. (Scheme 66)
  5. Use the Sector Shaft Seal Replacer to install the sector shaft dust seal. (Scheme 67) Lubricate the steering gear sector shaft dust seal; use Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A.
  6. Remove the steering gear housing from the Bench Mounted Holding Fixture.
  7. Position the input shaft bearing in the valve housing and use the Input Shaft Bearing/Seal Tool Set and a press to seat the bearing. (Scheme 69)
  8. Use the Input Shaft Bearing/Seal Tool and a press to seat the power steering gear input shaft seal. (Scheme 69)
  9. Install the input shaft snap ring. (Scheme 63)
  10. Use the Input Shaft Bearing/Seal Tool to install the power steering gear input shaft seal dust seal. see scheme 73
  11. Mount the valve housing in the Bench Mounted Holding Fixture. see scheme 74
  12. Install the power steering gear input shaft and control into the valve housing. see scheme 75
  13. Position the power steering gear race nut into the valve housing. (Scheme 60)
  14. Use the Adjuster and Locknut Wrench to tighten the race nut to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering__torque-specifications). (Scheme 60)
  15. Install the valve housing set screw, and tighten to specification, See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering__torque-specifications). (Scheme 59)
  16. Remove the valve housing from the Bench Mounted Holding Fixture and position the piston on the worm gear. (Scheme 57)
  17. Install the steering gear ball return guide on the piston. (Scheme 56)
  18. Rotate the piston while holding the steering gear ball return guide and install the 28 ball bearings into the opening in the ball guide. (Scheme 56)
  19. Install the steering gear ball return guide clamps, install the bolts and tighten to specification, See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering__torque-specifications).
  20. Install a new gasket. (Scheme 55)
  21. Lubricate and install the seal on the piston. Use Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A.
  22. Install the piston assembly into the steering gear housing. (Scheme 54)
  23. Rotate the teeth so they are on the same plane as the steering gear sector shaft. see scheme 78
  24. Loosely install the valve housing bolts and the identification tag, if so equipped. see scheme 79
  25. Lubricate the O-ring on the sector shaft housing cover. see scheme 80 Use Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A.
  26. Rotate the housing clockwise and install the sector shaft into the sector shaft housing. see scheme 81
  27. Install the sector shaft lock nut. (Scheme 51)
  28. Install the sector shaft and housing assembly. (Scheme 50)
  29. Tighten the steering gear sector shaft housing cover bolts to specification. «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering__torque-specifications). (Scheme 48)
  30. Tighten the bolts to specification. «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering__torque-specifications).
  31. Install steering gear in vehicle. Perform meshload adjustment. See «STEERING GEAR MESHLOAD ADJUSTMENT»(/ford/econoline/i-1985-2013/remont/manual-power-steering/#power-steering__steering-gear-meshload-adjustment) under ADJUSTMENTS & INSPECTION.

GENERAL SPECIFICATIONS

ItemSpecification
Steering Wheel Turn Effort23 Ft. Lbs. (31 N.m)
Steering Wheel Free Play0.12 In. (3 mm)
Ball Stud Free Play (Maximum)0.04 In. (1 mm)
Steering Gear
TypeXR50 (QSC) Recirculating Ball
Ratio17:1
Steering Gear Turns (Stop-To-Stop)4
Worn Bearing Preload (For Inspection Purposes Only)8 INCH Lbs. (0.9 mm)
Total Meshload Over Worn Bearing Preload Over Ends (For Inspection Purposes Only)2-7 INCH Lbs. (0.23-0.80 N.m)
Worn To Piston Preload (For Inspection Purposes Only)1-3 INCH Lbs. (0.11-0.34 N.m)
Steering Pump
TypeCIII
Flow Rate @ 165°-175°F (74°-80° C) And Engine Speed Set At 1500 RPM2.8-3.2 Gal./Min. (10.6-12.0 Litres/Min.)
Maximum Pressure @ 165°-175°F (74°-80°C) And Engine Speed Set at 1500 RPM150 psi (1034 kPa)
Minimum Flow Rate @ 165°-175°F (74°-80°C), Power Steering Analyzer Set At 750 psi (5102 kPa) And Engine Speed Set At Idle1.4 Gal./Min. (5.3 Litres/Min.)
Relief Pressure1,300-1,430 psi (9,000-9,900 kPa)
Lubrication
MERCON® Multi-Purpose ATF XT-2-QDXMERCON®

GENERAL SPECIFICATIONS

SPECIAL TOOLS

Tool NumberToll Description
211-D027 (D90P-3517-A) or EquivalentTeflon® Seal Replacer Set
211-016 (T69L-10300-B)Steering Pump Pulley Remover
211-185 (T91P-3A733-A)Steering Pump Pulley Replacer
211-003 (T64P-3590-F)Pitman Arm Puller
211-012 (T66P-3553-B)Adjuster and Locknut Wrench
307-003 (T57L-500-B)Bench Mounted Holding Fixture
211-S005 (T65P-3524-A)Input Shaft Bearing/Seal Tool
308-001 (T58L-101-B)Puller
211-044 (T77L-3576-A)Sector Shaft Seal Replacer
023-R0007 or EquivalentDial Thermometer 0-220°F
105-R0053 or EquivalentHand Held Automotive Meter
211-F001 (014-00207) or EquivalentPower Steering Analyzer
211-034 (T74P-3504-Y)Spring Scale
418-F102 (007-00061) or EquivalentTach Adapter

SPECIAL SERVICE TOOLS

TORQUE SPECIFICATIONS

ApplicationFt. Lbs. (N.m)
Input Shaft Race Retaining Nut55-90 (75-122)
Intermidiate Shaft Pinch Bolt16-21 (22-28)
Meshload Adjuster Lock Nut20-25 (27-34)
Power Steering Pump Upper Bolts15-22 (20-30)
Power Steering Pump Lower Bolt15-22 (20-30)
Pressure Hose at Steering Gear13-17 (17-23)
Pressure Hose Fitting13-17 (17-23)
Return Hose Fitting at Steering Gear13-17 (17-23)
Sector Shaft Housing Bolts45-55 (61-75)
Steering Damper Right Hand Bracket Nut50-86 (68-92)
Steering Damper Left Hand Bracket Nut50-86 (68-92)
Steering Gear-To-Frame Bolts51-68 (69-92)
Steering Gear Sector Shaft Arm-To-Sector Shaft Nut170-228 (230-310)
Steering Sector Shaft Arm Drag Link Castellated Nut57-76 (77-104)
Tie Rod Adjusting Sleeve Bolts30-42 (40-57)
Tie Rod End-To-Drag Link Castellated Nut56-84 (76-114)
Tie Rod End-To-Spindle Castellated Nut56-84 (76-114)
Valve Housing Bolt30-44 (40-60)
Valve Housing-To-Gear Bolts35-49 (48-67)
Wheel Lug Nuts (E150, 5-Lug)74-133 (100-180)
Wheel Lug Nuts (E250/350/Super Duty, 8-Lug)126-170 (170-230)
INCH Lbs. (N.m)
Power Steering Cooler Bolts80-106 (9-12)
Steering Gear Allen Head Race Lock Nut15-25 (1.7-2.8)
Steering Gear Ball Return Guide Clamp Bolts45-62 (5-7)
Steering Wheel Rotating Torque13 (1.5)
Sector Shaft Rotating Torque18 (2.0)

TORQUE SPECIFICATIONS

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