Home ReviewsRefund
Home/Ford/Five Hundred/Ford Five Hundred I (2004-2007)/Repair manual/Manual & Power Steering/Power Steering System
Contents Section: Manual & Power Steering All sections

Power Steering System Ford Five Hundred I

Manual & Power Steering 14 illustrations ~1625 words

GENERAL SPECIFICATIONS

ItemSpecification
Lubricants
MERCON® Multi-Purpose (ATF) Transmission Fluid XT-2-QDXMERCON®
Premium Long-Life Grease XG-1-CESA-M1C75-B

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

DescriptionNm
Degas bottle mounting bolts7
Inner tie-rod100
Intermediate shaft-to-steering gear bolt25
Power steering fluid cooler bolts6
Power steering fluid reservoir nuts9
Power steering line clamp plate bolt20
Power steering pressure line bracket-to-engine bolts10
Power steering pressure line fitting65
Power steering pressure line fitting-to-pump adapter65
Power steering pressure line bracket-to-engine bolts10
Power steering pump nuts25
Power steering return line bracket-to-frame bolts10
Steering gear nuts117
Tie-rod end jam nuts80
Tie-rod end nuts90

TORQUE SPECIFICATIONS

The power steering system consists of the following components

  1. Power steering pump
  2. Power steering fluid reservoir
  3. Rack-and-pinion steering gear
  4. Power steering fluid cooler
  5. Power steering pressure and return lines/hoses

Scheme 1

Scheme 1: Power Steering System - Exploded View
Scheme 1: Power Steering System - Exploded View
  1. For additional information, refer to the procedures in this section.

Material

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

MATERIAL SPECIFICATION - POWER STEERING FLUID RESERVOIR

Removal and Installation

CAUTIONWhen repairing the power steering system, care should be taken to prevent the entry of contaminants or premature failure of the power steering components can result.

Note. Do not allow power steering fluid to contact the engine accessory drive belt.

  1. Using a suitable suction device, drain the power steering fluid reservoir.
  2. Release the clamp and disconnect the power steering fluid cooler-to-reservoir hose from the power steering fluid reservoir.
  3. Remove the 2 nuts and reposition the power steering fluid reservoir. To install, tighten to 9 Nm (80 lb-in).
  4. Release the clamp and disconnect the power steering suction hose from the power steering fluid reservoir.
  5. Remove the power steering fluid reservoir.
  6. To install, reverse the removal procedure. Fill the power steering system. For additional information, refer to «STEERING SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/manual-power-steering/#steering-system-general-information) .

Special Tool(s)

SPECIAL TOOL - POWER STEERING PUMP Installer Set, Teflon® Seal 211-D027 (D90P-3517-A) or equivalent

Scheme 2

Scheme 2: Special Tool(s)
Scheme 2: Special Tool(s)
ItemSpecification
MERCON® Multi-Purpose (ATF) Transmission Fluid XT-2-QDXMERCON®

MATERIAL SPECIFICATION - POWER STEERING PUMP

Removal

CAUTIONWhen repairing the power steering system, care should be taken to prevent the entry of contaminants or premature failure of the power steering components can result.

Note. Do not allow power steering fluid to contact the engine accessory drive belt.

Scheme 3

Scheme 3
Scheme 3

Scheme 4

Scheme 4
Scheme 4

Scheme 5

Scheme 5
Scheme 5
  1. Disconnect the windshield washer motor electrical connector.
  2. Remove the 2 bolts and position aside the degas bottle. Disconnect the fill sensor electrical connector.
  3. Release the 2 retainers and position aside the engine wiring harness. Disconnect the 4 electrical connectors.
  4. Remove the engine accessory drive belt. For additional information, refer to «ACCESSORY DRIVE»(/ford/five-hundred/i-2004-2007/remont/accessory-drive-belts/#accessory-drive-system) .
  5. Remove the power steering fluid reservoir. For additional information, refer to «POWER STEERING FLUID RESERVOIR»(/ford/five-hundred/i-2004-2007/remont/manual-power-steering/#power-steering-system) .
  6. Disconnect the power steering pressure line fitting. Discard the Teflon® seal.
  7. Disconnect the power steering pressure line fitting-to-pump adapter. Discard the Teflon® seal.
  8. Remove the 3 nuts and the power steering pump. Rotate the power steering pump pulley to access the nuts through the holes.

Installation

  1. Using the special tool, install a new Teflon® seal on the power steering pressure line fitting and the power steering pressure line fitting-to-pump adapter.
  2. Install the power steering pump and the 3 nuts. Rotate the power steering pump pulley to access the nuts through the holes. Tighten to 25 Nm (18 lb-ft).
  3. Install the power steering pressure line fitting-to-pump adapter. Tighten to 65 Nm (48 lb-ft).
  4. Connect the power steering pressure line fitting. Tighten to 65 Nm (48 lb-ft).
  5. Install the power steering fluid reservoir. For additional information, refer to «POWER STEERING FLUID RESERVOIR»(/ford/five-hundred/i-2004-2007/remont/manual-power-steering/#power-steering-system) .
  6. Install the engine accessory drive belt. For additional information, refer to «ACCESSORY DRIVE»(/ford/five-hundred/i-2004-2007/remont/accessory-drive-belts/#accessory-drive-system) .
  7. Position the degas bottle and install the 2 bolts. Tighten to 7 Nm (62 lb-in). Connect the fill sensor electrical connector.
  8. Connect the windshield washer motor electrical connector.
  9. Fill the power steering system. For additional information, refer to «STEERING SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/manual-power-steering/#steering-system-general-information) .

SPECIAL TOOL - POWER STEERING PUMP PULLEY Remover, Power Steering Pump Pulley 211-016 (T69L-10300-B) Installer, Power Steering Pump Pulley 211-185 (T91P-3A733-A)

Scheme 6

Scheme 6: Special Tool(s)
Scheme 6: Special Tool(s)

Scheme 7

Scheme 7
Scheme 7

Scheme 8

Scheme 8
Scheme 8
  1. Disconnect the windshield washer motor electrical connector.
  2. Remove the 2 bolts and position aside the degas bottle. Disconnect the fill sensor electrical connector.
  3. Release the 2 retainers and position aside the engine wiring harness. Disconnect the 4 electrical connectors.
  4. Remove the engine accessory drive belt. For additional information, refer to «ACCESSORY DRIVE»(/ford/five-hundred/i-2004-2007/remont/accessory-drive-belts/#accessory-drive-system) .
  5. Using the special tool, remove the power steering pump pulley.
  1. Using the special tool, install the power steering pump pulley.
  2. Install the engine accessory drive belt. For additional information, refer to «ACCESSORY DRIVE»(/ford/five-hundred/i-2004-2007/remont/accessory-drive-belts/#accessory-drive-system) .
  3. Position the wiring harness to the 2 retainers. Connect the 4 electrical connectors.
  4. Position the degas bottle and install the 2 bolts. Connect the fill sensor electrical connector. Tighten to 7 Nm (62 lb-in).
  5. Connect the windshield washer motor electrical connector.

SPECIAL TOOL - POWER STEERING PUMP TO STEERING GEAR PRESSURE LINE Installer Set, Teflon® Seal 211-D027 (D90P-3517-A) or equivalent

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

MATERIAL SPECIFICATION - POWER STEERING PUMP TO STEERING GEAR PRESSURE LINE

CAUTIONWhile repairing the power steering system, care should be taken to prevent the entry of contaminants or premature failure of the power steering components can result.

Note. Do not allow power steering fluid to contact the engine accessory drive belt.

Scheme 9

Scheme 9
Scheme 9
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/five-hundred/i-2004-2007/remont/hoistjack/#jacking-lifting) .
  2. Remove the power steering fluid reservoir. For additional information, refer to «POWER STEERING FLUID RESERVOIR»(/ford/five-hundred/i-2004-2007/remont/manual-power-steering/#power-steering-system) .
  3. Disconnect the power steering pressure line fitting. Discard the Teflon® seal.
  4. Remove the power steering pressure line bracket-to-engine bolt.
  5. Remove the 2 power steering pressure line bracket-to-engine bolts on the cylinder head.
  6. Disconnect the power steering pressure (PSP) switch electrical connector.
  7. Remove the power steering line clamp plate bolt, rotate the clamp plate, disconnect and remove the power steering pressure line from the steering gear. Discard the O-ring seal.
  1. Using the special tool, install a new Teflon® seal on the power steering pressure line fitting at the pump.
  2. Position and connect the power steering pressure line to the steering gear, rotate the clamp plate into position, and install the bolt. Install a new O-ring seal. Tighten to 20 Nm (15 lb-ft).
  3. Connect the PSP switch electrical connector.
  4. Install the 2 power steering pressure line bracket-to-engine bolts on the cylinder head. Tighten to 10 Nm (89 lb-in).
  5. Install the power steering pressure line bracket-to-engine bolt. Tighten to 10 Nm (89 lb-in).
  6. Install the power steering pressure line fitting on the power steering pump. Tighten to 65 Nm (48 lb-ft).
  7. Install the power steering fluid reservoir. For additional information, refer to «POWER STEERING FLUID RESERVOIR»(/ford/five-hundred/i-2004-2007/remont/manual-power-steering/#power-steering-system) .
  8. Fill the power steering system. For additional information, refer to «STEERING SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/manual-power-steering/#steering-system-general-information) .
ItemSpecification
MERCON® Multi-Purpose (ATF) Transmission Fluid XT-2-QDXMERCON®

MATERIAL SPECIFICATION - STEERING GEAR TO FLUID COOLER RETURN HOSE

CAUTIONWhile repairing the power steering system, care should be taken to prevent the entry of contaminants or premature failure of the power steering components can result.
  1. Remove the radiator grille. For additional information, refer to «EXTERIOR TRIM AND ORNAMENTATION»(/ford/five-hundred/i-2004-2007/remont/exteriorinterior-trim/#exterior-trim-and-ornamentation) .
  2. Release the clamp and disconnect the power steering return line-to-fluid cooler hose. Allow the power steering fluid to drain into a suitable container.
  3. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/five-hundred/i-2004-2007/remont/hoistjack/#jacking-lifting) .
  4. Remove the power steering line clamp plate bolt, rotate the clamp plate, and disconnect the power steering return line from the power steering gear. Discard the O-ring seal. To install, tighten to 20 Nm (15 lb-ft).
  5. Remove the 3 power steering return line bracket-to-frame bolts. To install, tighten to 10 Nm (89 lb-in).
  6. To install, reverse the removal procedure. Install a new O-ring seal. Fill the power steering system. For additional information, refer to «BRAKE SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/brakes-control-systems/#brake-system-general-information) .
ItemSpecification
MERCON® Multi-Purpose (ATF) Transmission Fluid XT-2-QDXMERCON®

MATERIAL SPECIFICATION - POWER STEERING FLUID COOLER

CAUTIONWhen repairing the power steering system, care should be taken to prevent the entry of contaminants or premature failure of the power steering components can result.
  1. Remove the radiator grille. For additional information, refer to «EXTERIOR TRIM AND ORNAMENTATION»(/ford/five-hundred/i-2004-2007/remont/exteriorinterior-trim/#exterior-trim-and-ornamentation) .
  2. Release the clamp and disconnect the power steering return line-to-fluid cooler hose. Allow the fluid to drain into a suitable container.
  3. Release the clamp and disconnect the power steering fluid cooler-to-reservoir hose.
  4. Remove the 2 bolts and the power steering fluid cooler. To install, tighten to 6 Nm (53 lb-in).
  5. To install, reverse the removal procedure. Fill the power steering system. For additional information, refer to «STEERING SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/manual-power-steering/#steering-system-general-information) .
ItemSpecification
MERCON® Multi-Purpose (ATF) Transmission Fluid XT-2-QDXMERCON®

MATERIAL SPECIFICATION - STEERING GEAR

Scheme 10

Scheme 10
Scheme 10
CAUTIONWhen repairing the power steering system, care should be taken to prevent the entry of contaminants or premature failure of the power steering components can result.

Scheme 11

Scheme 11
Scheme 11
  1. Turn the steering wheel to the straight-ahead position and remove the ignition key.
  2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/five-hundred/i-2004-2007/remont/hoistjack/#jacking-lifting) .
  3. Remove the 2 tie-rod end nuts. To install, tighten to 90 Nm (66 lb-ft).
  4. Disconnect the tie-rod ends from the steering knuckle.
  5. Remove the power steering line clamp plate bolt. To install, tighten to 20 Nm (15 lb-ft).
  6. Rotate the clamp plate and disconnect the power steering pressure and return lines from the steering gear. Allow the power steering fluid to drain into a suitable container. Discard the 2 O-ring seals.
  7. Release the intermediate shaft boot bearing clamp from the intermediate shaft boot. Using a suitable tool, open the intermediate shaft boot bearing clamp and release the boot from the intermediate shaft. Retain the intermediate shaft boot bearing clamp in the open position.
  8. Remove the intermediate shaft-to-steering gear bolt. To install, tighten to 25 Nm (18 lb-ft).
  9. Remove the 2 steering gear nuts and bolts. To install, tighten to 117 Nm (86 lb-ft).
  10. Remove the steering gear from the left side of the vehicle.
  11. To install, reverse the removal procedure. Fill the power steering system. For additional information, refer to «STEERING SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/manual-power-steering/#steering-system-general-information) . Check and, if necessary, adjust the front toe. For additional information, refer to «SUSPENSION SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/suspension-front/#suspension-system-general-information) .

SPECIAL TOOL - INNER TIE ROD Inner Tie-Rod Socket Tool 211-D029 or equivalent Installer, Constant Velocity Joint Boot Clamp 205-343 (T95P-3514-A)

Scheme 12

Scheme 12: Special Tool(s)
Scheme 12: Special Tool(s)
ItemSpecification
Premium Long Life Grease XG-l-CESA-M1C75-B

MATERIAL SPECIFICATION - INNER TIE ROD

Scheme 13

Scheme 13
Scheme 13
CAUTIONThe boots and clamps are designed to provide an airtight seal and protect the internal components of the steering gear. If the seal is not airtight the vacuum generated during turning will draw water and contamination into the gear, causing premature damage.
CAUTIONZip ties do not produce an airtight seal and must not be used.
CAUTIONThe inner ball joint grease is not compatible with water and contamination trapped in the grease will degrade the life of the joint.
CAUTIONIf present, the orientation of the vent tube must be noted so the boots and vent tubes can be installed in the correct location.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/five-hundred/i-2004-2007/remont/hoistjack/#jacking-lifting) .
  2. Loosen the tie-rod end jam nut.
  3. Remove the tie-rod end nut.
  4. Remove the tie-rod end.
  5. Remove the jam nut.
  6. Remove the outer bellows clamp.
  7. Remove and discard the inner bellows clamp and remove the bellows.
  8. Remove the inner tie-rod bellows.
  9. Using the special tool, remove the inner tie-rod.

Scheme 14

Scheme 14: Installation
Scheme 14: Installation
  1. Using the special tool, install the inner tie-rod. Tighten to 100 Nm (74 lb-ft).
  2. Position the inner tie-rod bellows clamp and install the bellows.
  3. Using the special tool, install the inner bellows clamp.
  4. Install the outer bellows clamp.
  5. Thread the tie-rod end jam nut onto the inner tie-rod.
  6. Install the outer tie-rod to the inner tie-rod.
  7. Install the tie-rod end nut. Tighten to 90 Nm (66 lb-ft).
  8. Tighten the tie-rod end jam nut. Tighten to 80 Nm (59 lb-ft).
  9. Check and, if necessary, adjust the front toe. For additional information, refer to «SUSPENSION SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/suspension-front/#suspension-system-general-information) .

More articles — Steering