Steering System - Variable Assist Ford Probe I

DESCRIPTION

The Variable Assist Power Steering (VAPS) control system automatically adjusts power steering fluid pressure to provide light steering effort during low speed driving and firm steering during high speed driving.

The VAPS system consists of a control module, steering angle sensor, vehicle speed sensor, solenoid valve, power steering pump, rack and pinion and inter-connecting hoses. The system continuously monitors steering wheel angle and vehicle speed to adjust steering system pressure. (Scheme 1)

OPERATION

The VAPS system controls power steering fluid pressure through solenoid valve, mounted on rack and pinion. Solenoid valve opens to provide full power assist at maneuvers less than 6.2 MPH or when steering wheel is moved more than 45 degrees in either direction. The control module has a 3-position slide switch ("H", "N" and "L") for 10 percent harder than normal, normal, or 10 percent lighter than normal steering effort.

Scheme 1

HARD STEERING UNDER ALL CONDITIONS

Check solenoid valve, vehicle speed sensor, steering angle sensor, wiring harness and VAPS control module. Go to TESTING .

EXCESSIVELY LIGHT STEERING AT HIGH SPEEDS

Check solenoid valve, vehicle speed sensor, wiring harness and VAPS control module. Go to TESTING .

EXCESSIVE NOISE

A high-pitched sound may be heard from steering gear valve and/or pump when steering wheel is turned to either full lock position. The noise also may occur when steering wheel is moved slowly. Manufacturer says the noise is caused by power steering fluid flow and "in no way" will affect performance or service life of components in system.

TESTING PROCEDURE

Note. Power steering pump pressure should be 1066-1138 psi (7355-7846 kPa) with fluid temperature between 122-140°F (50-60°C) at 1000-1500 RPM and pressure gauge valve closed for no more than 15 seconds. If pressure is low, repair or replace pump.

A thorough visual inspection should precede all VAPS testing. See TROUBLE SHOOTING , along with a corresponding circuit and connector wiring diagram. An Analog Volt-Ohm Meter (VOM) is needed to access VAPS test connector.

There is no warning light to signal driver about power steering control system problems. The control module does NOT store any fault codes. Trouble codes are accessed through VAPS test connector, below windshield wiper motor.

Information concerning possible problems can be gained through 3 specialized tests

1. «KEY ON ENGINE RUNNING TEST»(/ford/probe/i-1988-1992/remont/manual-power-steering/#steering-system-variable-assist)
2. «CONTINUOUS MONITOR TEST»(/ford/probe/i-1988-1992/remont/manual-power-steering/#steering-system-variable-assist)
3. «PINPOINT TESTS»(/ford/probe/i-1988-1992/remont/manual-power-steering/#steering-system-variable-assist)

The system's integrity and processing capability are tested. Tests also verify sensors and actuators operate properly.

Repair any mechanical fault before testing or false diagnostic information may be obtained. Complete, in order, each test before going to PINPOINT TESTS or replacement of non-defective parts may result. Note location of 3-position slide switch on VAPS control module before entering diagnostics. (Scheme 2)

Scheme 2

Note. If vehicle passes all phases of KEY ON ENGINE RUNNING TEST and CONTINUOUS MONITOR TEST, the problem may be mechanical. When directed to PINPOINT TESTS, look carefully at wiring diagram. Any time a repair is made, KEY ON ENGINE RUNNING TEST should be repeated as a double check.

VISUAL INSPECTION

1. Check steering gear and linkage for damage, leaks, cracks and proper mounting. Check tire pressure.
2. Check VAPS wiring harness for proper connections, bent or broken pins, corrosion, loose wires and proper routing. Check control module, sensors and actuators for physical damage. Make repairs before continuing.
3. Set parking brake, place shifter in Park position (Neutral on manual transaxle) and block wheels. Turn off all electrical accessories. Proceed to «EQUIPMENT CONNECTION»(/ford/probe/i-1988-1992/remont/manual-power-steering/#steering-system-variable-assist__equipment-connection) .

EQUIPMENT CONNECTION

Set analog Volt/Ohm Meter (VOM) to 20-volt (DC) scale. Locate VAPS test connector under hood, below windshield wiper motor. Connect VOM positive lead to Yellow/Black wire terminal and negative lead to Black wire terminal.

Test Procedure

Turn ignition off to reset control module before each test. Verify vehicle has completed VISUAL INSPECTION. Start vehicle and ensure steering wheel is straight. Turn on analog VOM to activate test. Count needle sweeps and record all service codes displayed. The chart shows voltmeter needle sweeps. Notice same code pattern can sometimes indicate different faults in different test steps. (Scheme 3)

Scheme 3

Test Results

Begin with STEP A in left column, following instructions in test step column. Ignore codes retrieved with engine NOT running. A pass code in ACTION TO TAKE column indicates no faults detected. Proceed to CONTINUOUS MONITOR TEST .

Note. If a constant 12 volts is indicated, a shorted circuit to VAPS control module may exist. Diagnose test connector circuit indicated in PINPOINT TEST Q1 through PINPOINT TEST Q7 to continue. Repair test connector circuit. Repeat KEY ON ENGINE RUNNING test and proceed with other tests before replacing control module.

Verify pass code in all KEY ON ENGINE RUNNING test steps before continuing. CONTINUOUS MONITOR TEST allows technician to simulate intermittent fault. Connect analog VOM to VAPS test connector. Start engine to enter continuous monitor mode. Tap, move and wiggle suspect sensor and/or harness, while running all steps of KEY ON ENGINE RUNNING TEST. Follow appropriate ACTION TO TAKE. (Scheme 3)

The CONTINUOUS MONITOR TEST can aid in diagnosing intermittent VAPS circuit failures. If VOM indicates a fault (short or open), a corresponding code pattern will be indicated. After determining affected circuits, a close check of harness and connectors should be made.

USING CONTINUOUS MONITOR MODE

If a code pattern is displayed

1. Visually inspect sensor.
2. Lightly tap on sensor.
3. Push/pull on sensor harness connector. DO NOT disconnect connector yet.
4. Shake harness vigorously, working from sensor connector toward dash panel and from dash panel to control module in short sections.
5. If no sign of intermittent, carefully disconnect sensor from harness. Visually inspect harness at both ends for corrosion, bad crimps and improperly seated terminals. Reconnect after inspection.
6. Carefully disconnect VAPS control module and inspect terminals. Remove only terminals associated with sensor being inspected.
7. If VOM does NOT give a positive intermittent indication, reconnect all terminals and connectors.

PRE-TEST INSTRUCTIONS

Run PINPOINT TESTS only after completing the following

1. «VISUAL INSPECTION»(/ford/probe/i-1988-1992/remont/manual-power-steering/#steering-system-variable-assist__visual-inspection)
2. «KEY ON ENGINE RUNNING TEST»(/ford/probe/i-1988-1992/remont/manual-power-steering/#steering-system-variable-assist)
3. «CONTINUOUS MONITOR TEST»(/ford/probe/i-1988-1992/remont/manual-power-steering/#steering-system-variable-assist)
4. Each PINPOINT TEST assumes a fault has been detected. Failure to comply with correct testing order can result in error.
5. Test results depend on proper operation of related parts. Correct any defects in this area before passing quick test.
6. DO NOT replace parts unless test results indicate it.
7. When one or more service codes are shown, start with first code received.
8. DO NOT measure voltage or resistance at control module or connect any test lights unless specified.
9. Isolate both ends of a circuit and turn ignition off whenever checking for shorts or continuity, unless specified.
10. Disconnect solenoids and switches from harness before measuring for continuity, resistance or energizing with 12-volt source.
11. In using pinpoint test, follow each step in order, starting from first step in appropriate test. Follow each step until fault is found.
12. An open is defined as any resistance reading more than 5 ohms unless otherwise specified.
13. A short is defined as any resistance reading less than 10,000 ohms to ground, unless otherwise specified.

Variable Assist Power Steering Wiring Diagram. Scheme 4

SYSTEM INTEGRITY

Visually inspect ALL wiring, connectors and components for evidence of overheating, insulation damage, looseness, shorting or other damage. If problems exist, service as required. If NO problems exist, proceed to PINPOINT TEST A2 .

PINPOINT TEST A2 - SOLENOID FUNCTION CHECK

Disconnect solenoid valve connector. Apply 12 volts and ground to terminals and listen for solenoid actuation. If clicking is heard, proceed to PINPOINT TEST A3 . If NO clicking is heard, replace solenoid valve.

PINPOINT TEST A3 - SOLENOID RESISTANCE CHECK

Set VOM on 200-ohm scale. Measure resistance between solenoid terminals. If resistance is between 3.4-6.9 ohms, proceed to PINPOINT TEST A4 . If resistance is NOT within specification, replace solenoid.

PINPOINT TEST A4 - SOLENOID CIRCUIT RESISTANCE

Disconnect VAPS control module connector and solenoid valve connector. Turn ignition off. Set VOM on 200-ohm scale. Measure resistance between Blue/Green wires in each connector. Measure resistance between Blue/Black wires in each connector. If resistances are less than 5 ohms, proceed to PINPOINT TEST A5 . If resistances are NOT within specification, repair open in wire.

PINPOINT TEST A5 - SOLENOID CIRCUIT SHORT

Leave control module and solenoid valve disconnected. Disconnect battery. Set VOM on 200K/ohm scale. Measure resistance between

1. Blue/Black wire in VAPS control module connector and chassis ground.
2. Blue/Black wire and Blue/Green wire in VAPS control module connector.
3. Blue/Green wire in VAPS control module connector and chassis ground.
4. Blue/Green wire and Black/Green wire in VAPS control module connector.

If all resistances are more than 10K ohms, proceed to PINPOINT TEST Q1 through PINPOINT TEST Q7 . If resistances are NOT within specifications, repair wires in question between control module and solenoid for shorts to ground.

VAPS Connector Identification. Scheme 5

PINPOINT TEST B1 - SYSTEM INTEGRITY

Visually inspect ALL wiring, connectors and components for evidence of overheating, insulation damage, looseness, shorting or other damage. If problems exist, service as required. If NO problems exist, proceed to PINPOINT TEST B2 .

PINPOINT TEST B2 - IGNITION COIL VOLTAGE

Disconnect VAPS control module connector. Start engine. Measure voltage between Yellow/Blue wire in VAPS control module connector and chassis ground. If voltage is more than 10 volts, proceed to PINPOINT TEST Q1 through PINPOINT TEST Q7 . If voltage is NOT within specification, proceed to PINPOINT TEST B3 .

PINPOINT TEST B3 - CIRCUIT CONTINUITY

Leave VAPS control module connector disconnected. Disconnect ignition coil connector (single wire on non-turbo model or 4-wire connector on turbo models). Set VOM on 200-ohm scale. Measure resistance between Yellow/Blue wires at coil connector and VAPS control module connector. If resistance is less than 5 ohms, proceed to PINPOINT TEST B4 . If resistance is NOT within specification, service wire in question for open between coil and module.

PINPOINT TEST B4 - CIRCUIT SHORT/VAPS CHECK

Leave VAPS control module disconnected. Disconnect battery. Set VOM on 200K/ohm scale. Measure resistance between Yellow/Blue wire in VAPS control module connector and chassis ground. Measure resistance between Yellow/Blue wire and Black/Green wire. If resistance is more than 10K ohms, proceed to PINPOINT TEST Q1 through PINPOINT TEST Q7 . If resistance is NOT within specification, repair Yellow/Blue wire between coil and control module for short to ground.

PINPOINT TEST C1 - SYSTEM INTEGRITY

Visually inspect ALL wiring, connectors and components for evidence of overheating, insulation damage, looseness, shorting or other damage. If problems exist, service as required. If NO problems exist, proceed to PINPOINT TEST C2 .

PINPOINT TEST C2 - STEERING SENSOR RESISTANCE

Turn ignition off. Remove steering column cover and disconnect steering angle sensor connector. Set steering wheel so wheels are straight. Measure resistance between

STEERING ANGLE SENSOR RESISTANCE

If resistances are within specifications, proceed to PINPOINT TEST C3 . If resistance is NOT within specifications, replace steering angle sensor.

PINPOINT TEST C3 - STEERING ANGLE SENSOR CHECK

1. Disconnect steering angle sensor connector. Set steering wheel straight. Set VOM on 200K/ohm scale. Measure resistance between Green and Green/White wires while turning steering wheel slowly from straight to 180 degrees right. If resistance increases from 25K ohms to approximately 50K ohms, proceed to «PINPOINT TEST C4»(/ford/probe/i-1988-1992/remont/manual-power-steering/#steering-system-variable-assist__pinpoint-test-c4-steering-angle) . If resistance is NOT within specification, replace steering angle sensor.
2. With steering wheel straight, measure resistance between Green and Green/White wires. If resistance is between 20-30K ohms, proceed to «PINPOINT TEST C4»(/ford/probe/i-1988-1992/remont/manual-power-steering/#steering-system-variable-assist__pinpoint-test-c4-steering-angle) . If resistance is NOT within specification, replace steering angle sensor.

PINPOINT TEST C4 - STEERING ANGLE SENSOR CHECK

1. Disconnect steering angle sensor connector. Set steering wheel straight. Set VOM on 200K scale. Measure resistance between Green and Green/White wires while turning steering wheel slowly from straight to 180 degrees left. If resistance decreases from 25K ohms to approximately 200 ohms, proceed to «PINPOINT TEST C5»(/ford/probe/i-1988-1992/remont/manual-power-steering/#steering-system-variable-assist__pinpoint-test-c5-circuit-continuity) . If resistance is NOT within specification, replace steering angle sensor.
2. With steering wheel straight, measure resistance between Green and Green/Yellow wires. If resistance is between 40-60K ohms, proceed to «PINPOINT TEST C5»(/ford/probe/i-1988-1992/remont/manual-power-steering/#steering-system-variable-assist__pinpoint-test-c5-circuit-continuity) . If resistance is NOT within specification, replace steering angle sensor.

PINPOINT TEST C5 - CIRCUIT CONTINUITY CHECK

Disconnect steering angle sensor connector and VAPS control module connector. Set VOM on 200-ohm scale. Measure resistance at each connector between: 2 Green wires, 2 Green/White wires and 2 Green/Yellow wires. If resistances are less than 5 ohms, proceed to PINPOINT TEST C6 . If resistances are NOT within specification, repair specific wire as necessary.

PINPOINT TEST C6 - SHORT TO VAPS CHECK

Disconnect VAPS control module connector and steering angle sensor connector. Disconnect Programmed Ride Control (PRC) module connector, under passenger's front seat. Turn ignition on. Set VOM on 20-volt scale. Measure voltage at VAPS control module connector between: Green wire and ground, Green/White wire and ground, and Green/Yellow wire and ground. If voltage readings are more than 0 volt, check/repair wire for shorts to VAPS control module. If voltage readings are NOT more than 0 volt, proceed to PINPOINT TEST C7 .

PINPOINT TEST C7 - SHORT TO GROUND CHECK

Turn ignition off. Disconnect VAPS control module connector and Programmed Ride Control (PRC) module connector. Set VOM on 200K/ohm scale. Measure resistance at VAPS module connector between: Green wire and ground, Green/White wire and ground, and Green/Yellow wire and ground. If resistances are more than 10K ohms, proceed to PINPOINT TEST Q1 through PINPOINT TEST Q7 . If resistances are NOT within specification, repair specific wire for shorts to ground.

PINPOINT TEST D1 - SYSTEM INTEGRITY

Visually inspect ALL wiring, connectors and components for evidence of overheating, insulation damage, looseness, shorting or other damage. If problems exist, service as required. If NO problems exist, proceed to PINPOINT TEST D2 .

PINPOINT TEST D2 - CIRCUIT CONTINUITY

Turn ignition off. Set VOM on 200-ohm scale. Measure resistance between Green/Red wire in VAPS control module connector and Green/Red wire in instrument panel connector. If resistance is more than 5 ohms, service Green/Red wire between VAPS control module and instrument panel for opens. If resistance is NOT within specifications, proceed to PINPOINT TEST D3 .

PINPOINT TEST D3 - SHORT TO VAPS CONTROL MODULE

Disconnect VAPS control module connector and instrument cluster connector. Disconnect Programmed Ride Control (PRC) connector. Turn ignition on. Set VOM on 20-volt scale. Measure voltage between Green/Red wire in VAPS module connector and chassis ground. If voltage is above 0 volt, service Green/Red wire for short to VPWR. On models with analog instrument panel, if voltage is NOT within specification, proceed to PINPOINT TEST D4 .

PINPOINT TEST D4 - VEHICLE SPEED SENSOR FUNCTION

Note. Testing procedure for digital (all electronic) display dashboard is not available.

For analog (electro-mechanical) display dash only. Turn ignition off. Remove instrument cluster. See VEHICLE SPEED SENSOR under REMOVAL & INSTALLATION. Disconnect speedometer cable from instrument cluster. Connect ohmmeter between Green/Red wire and Black wire of instrument cluster connector. Rotate speedometer cable connector on instrument cluster. If there are 4 continuity interruptions per speedometer cable rotation, proceed to PINPOINT TEST D5 . If there are NOT 4 continuity interruptions, replace speedometer subassembly.

Note. The vehicle speed sensor is part of the speedometer subassembly on analog display dash equipped vehicles. The speedometer subassembly must be replaced when vehicle speed sensor is defective.

PINPOINT TEST D5 - SHORT TO VAPS CONTROL MODULE

Turn ignition on. Put transmission in Park. Disconnect VAPS control module connector and instrument panel connector. Set VOM on 200K/ohm scale. Measure resistance between Green/Red wire in VAPS control module connector and ground. If resistance is less than 10K ohms, service Green/Red wire between instrument panel and module for shorts. If resistance is NOT less than specification, proceed to PINPOINT TEST Q1 through PINPOINT TEST Q7 .

PINPOINT TEST Q1 - SYSTEM INTEGRITY CHECK

Visually inspect ALL wiring, connectors and components for evidence of overheating, insulation damage, looseness, shorting or other damage. If problems exist, service as required. If no problems exist, proceed to PINPOINT TEST Q2 .

PINPOINT TEST Q2 - POWER TO VAPS CONTROL MODULE

Disconnect VAPS control module connector. Turn ignition on. Set VOM on 20-volt scale. Measure voltage between Black/Green wire and ground. If voltage is more than 10 volts, proceed to PINPOINT TEST Q3 . If voltage is NOT within specification, replace 10 amp fuse or repair Black/Green wire between module and fuse box.

PINPOINT TEST Q3 - VAPS CONTROL MODULE GROUND

Leave VAPS control module connector disconnected. Set VOM on 200-ohm scale. Measure resistance between Black wire and ground. If resistance is less than 5 ohms, proceed to PINPOINT TEST Q4 . If resistance is NOT within specification, repair Black wire between module and chassis ground for opens.

PINPOINT TEST Q4 - TEST CONNECTOR GROUND

Disconnect VAPS test connector from mounting. Set VOM on 200-ohm scale. Measure resistance between Black wire and ground. If resistance is less than 5 ohms, proceed to PINPOINT TEST Q5 . If NOT within specification, repair Black wire between test connector and ground.

PINPOINT TEST Q5 - MODULE/TEST CONNECTOR CONTINUITY

Disconnect VAPS control module connector. Set VOM on 200-ohm scale. Measure resistance between Yellow/Black wires in VAPS test connector and module. If resistance is less than 5 ohms, proceed to PINPOINT TEST Q6 . If resistance is NOT within specification, repair Yellow/Black wire between module and test connector for opens.

PINPOINT TEST Q6 - TEST CONNECTOR CIRCUIT SHORT

Leave VAPS control module connector disconnected. Turn ignition on. Set VOM on 20-volt scale. Measure voltage between Yellow/Black wire and ground. If voltage is more than 0 volt, repair Yellow/Black wire between module and VAPS test connector for shorts. If voltage is NOT within specifications, proceed to PINPOINT TEST Q7 .

PINPOINT TEST Q7 - TEST CONNECTOR SHORT

Leave VAPS control module connector disconnected. Turn ignition off. Set VOM on 200K/ohm scale. Measure resistance between Yellow/Black wire and ground. If resistance is more than 10K ohms, replace VAPS control module. If resistance is NOT within specifications, repair Yellow/Black wire between module and ground for shorts.

RACK & PINION PRELOAD

Note. Readjusting rack yoke preload will seldom cure hard steering or poor power steering wheel return. Check for damage from hitting a curb or tight components.

Remove rack and pinion. See RACK & PINION R & I under REMOVAL & INSTALLATION. Measure pinion torque using an inch-pound torque wrench and Pinion Torque Adapter (T88C-3504-BH). Torque should be 88.5-123.9 INCH lbs. (10-14 N.m). If pinion nut is not within specification, loosen lock nut.

Using Yoke Torque Gauge (T88C-3504-AH), torque adjust cover to 7.2 ft. lbs. (9.8 N.m) and then loosen. Torque adjust cover to 3.6 ft. lbs. (4.9 N.m) and loosen adjust cover 45 degrees. Using yoke lock nut wrench, tighten to 36-43 ft. lbs. (49-58 N.m).

Removal

Raise vehicle. Remove wheel. Remove cotter pin and tie rod attaching nut. Separate both tie rods from steering knuckles with Tie Rod Separator (T85M-3395-A). If tie rod end will not separate easily, strike steering knuckle with brass hammer to shock taper. Mark an aligning stripe on tie rod end, jam nut and tie rod. (Scheme 6) Loosen jam nut. Remove tie rod end.

Scheme 6

Installation

Thread jam nut and tie rod onto tie rod end. Align index mark on tie rod end, jam nut and tie rod. Torque jam nut to 51-72 ft. lbs. (69-98 N.m). Connect tie rod end to steering knuckle. Tighten attaching nut to 22-33 ft. lbs. (30-45 N.m). Install wheel. Lower vehicle.

1. Raise vehicle. Remove wheels. Disconnect negative battery cable.
2. Remove tie rod ends. See «TIE ROD ENDS»(/ford/probe/i-1988-1992/remont/manual-power-steering/#steering-system-variable-assist) under REMOVAL & INSTALLATION.
3. Remove plastic shield from both inner fender wheels.
4. Pull back steering column dust boot. Have an assistant turn steering column shaft until clamp bolt is accessible. Lock steering column.
5. Paint aligning mark on steering column pinion shaft and intermediate shaft lower universal joint. Remove clamp bolt from intermediate shaft lower universal joint.
6. Disconnect hydraulic lines from rack and pinion. Disconnect solenoid valve and pressure switch electrical connections.
7. Remove 6 rack and pinion mounting bolts. Lower rack and pinion onto crossmember. Slide rack and pinion to right until left tie rod clears left control arm. Slide to left and remove from vehicle.

1. Slide rack and pinion into position through right fenderwell. Position pinion shaft just below intermediate shaft joint.
2. Raise rack and pinion from under vehicle. Have an assistant guide pinion shaft into intermediate shaft. Ensure alignment marks meet.
3. Install 6 rack and pinion mounting bolts. Install clamp bolt in intermediate shaft lower universal joint. Tighten to specifications.
4. Connect hydraulic lines. Connect tie rod ends to steering knuckle arms.
5. Fill fluid reservoir. Connect negative battery cable. Install wheels. Lower vehicle.

START-UP PROCEDURE

Note. Follow START-UP PROCEDURE after removal of rack and pinion assembly or power steering pump to eliminate excessive steering system noise due to air trapped in system.

Removal & Installation

1. Disconnect coil wire.
2. Fill pump reservoir to specified level.
3. Crank engine and observe fluid level. Add fluid until level remains constant.
4. With wheels off floor, rotate steering wheel from lock-to-lock while cranking engine. Check fluid and fill as necessary.
5. Reconnect coil wire. Start engine and run for several minutes.
6. Rotate steering wheel from far left to far right several times.
7. Turn off engine and check fluid level.

The solenoid valve is mounted on left mounting bracket of rack and pinion assembly. It has 2 hydraulic line connections and a 2-wire connection (Blue/Green wire and Blue/Black wire). (Scheme 7) Further information about part replacement is not available.

Scheme 7

1. Remove right fender inner splash shield. Remove pump drive belt. Disconnect pressure and return hydraulic hoses from pump.
2. Remove 3 pump mounting bolts. Remove pump drive pulley, if necessary. Remove pump. (Scheme 8)

Scheme 8

1. If removed, install drive pulley and hub. Install 3 pump mounting bracket bolts and tighten to 27-34 ft. lbs. (37-46 N.m).
2. Connect pressure and return hydraulic hoses. Tighten to specification. Install drive belt. Fill system with fluid. Follow «START-UP PROCEDURE»(/ford/probe/i-1988-1992/remont/manual-power-steering/#steering-system-variable-assist__start-up-procedure) .

Disconnect negative battery cable. Remove driver's seat. (Scheme 1)and (Scheme 2). Further information about part replacement is not available.

Sensor is located in steering column, behind steering wheel. It uses a 3-wire connector with Green, Green/White and Green/Yellow wires. Further information about part replacement is not available.

Removal & Installation (Digital Instrument Cluster)

Disconnect negative battery cable. Disconnect 2-wire electrical connector from speed sensor in transaxle. Remove sensor mounting bolt. Pull sensor out of housing. To install, reverse removal procedure.

Removal & Installation (Analog Instrument Cluster)

1. Disconnect negative battery cable. Remove steering wheel. Remove 2 screws from steering column cover. Remove cover.
2. Remove 9 attaching screws from cluster module. Carefully pull cluster module for access to electrical connections. Disconnect 7 electrical connectors from cover. Remove ignition illumination bulb. Remove cluster module.
3. Loosen 2 cover hinge screws. Remove 6 screws from instrument cluster cover. Remove lower cluster cover panel. CAUTION: While removing lower cluster cover, be careful not to rip rubber seal between upper and lower cluster cover panels.
4. Remove 4 attaching screws from cluster. Disconnect 3 electrical connectors from back of cluster. Remove cluster.
5. Remove lens assembly. Remove 7 attaching screws and speedometer subassembly. To install, reverse removal procedure.

Disassembly

1. Mount rack and pinion in soft-jawed vise. Remove external hydraulic lines connecting valve body to rack housing. Remove dust boots.
2. Remove solenoid valve from left mounting bracket. Remove mounting bracket and rubber mounting bushings from rack and pinion. Remove tie rod ends. See «TIE ROD ENDS»(/ford/probe/i-1988-1992/remont/manual-power-steering/#steering-system-variable-assist) under REMOVAL & INSTALLATION. Using a chisel, uncrimp tie rod assembly lock washer. Using a 30 mm crowfoot wrench, remove tie rod from rack.
3. Remove adjust cover lock nut. Using Yoke Torque Gauge (T88C-3504-AH), remove adjust cover, spring and pressure pad. Using Outer Box Torque Adapter (T88C-3504-CH), remove outer box assembly. Remove pinion shaft oil seal with a screwdriver.

Reassembly

1. Inspect all parts and replace as required. Lubricate outer box assembly with ATF. Using Outer Torque Adapter (T88C-3504-CH), install outer box assembly.
2. Stake outer box assembly to rack housing using a punch. Apply a thin coat of grease to sealing lips of pinion seal. Install pinion shaft seal using Pinion Bearing Replacer (T88C-3504-BH).
3. Install pressure pad and spring into rack housing. Apply thread sealant to adjust cover. Using Torque Gauge (T88C-3504-AH), install adjust cover and tighten to 29-36 INCH lbs. (3.3-4.1 N.m). Loosen adjust cover 35 degrees. Using an inch-pound Torque Wrench and Pinion Adapter (T88C-3504-BH), measure pinion torque. The torque should be 88.5-123.9 INCH lbs. (10-14 N.m).
4. Install adjust cover lock nut. Tighten to 29-36 INCH lbs. (3.3-4.1 N.m). Mount rack in soft-jawed vise. Install tie rod assembly lock washer and tie rod. Tighten to 43-58 INCH lbs. (4.9-6.5 N.m). Bend lock washer tang to hold tie rod in place.
5. Slide a dust boot over tie rod and secure it on rack and pinion with mechanic's wire. Ensure boot is not twisted or dented. Secure outer boot clamp. Install tie rod end. To complete installation, reverse removal procedure.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

WIRING DIAGRAMS

For wiring diagrams, see SUSPENSION - PROGRAMMED RIDE CONTROL article in the SUSPENSION section.

See also:
• SUSPENSION - PROGRAMMED RIDE CONTROL
• TESTING
• TROUBLE SHOOTING
• EQUIPMENT CONNECTION
• VISUAL INSPECTION
• PINPOINT TEST Q1
• PINPOINT TEST Q7
• PINPOINT TEST A2
• PINPOINT TEST A3
• PINPOINT TEST A4
• PINPOINT TEST A5
• PINPOINT TEST B2
• PINPOINT TEST B3
• PINPOINT TEST B4
• PINPOINT TEST C2
• PINPOINT TEST C3
• PINPOINT TEST C4
• PINPOINT TEST C5
• PINPOINT TEST C6
• PINPOINT TEST C7
• PINPOINT TEST D2
• PINPOINT TEST D3
• PINPOINT TEST D4
• PINPOINT TEST D5
• PINPOINT TEST Q2
• PINPOINT TEST Q3
• PINPOINT TEST Q4
• PINPOINT TEST Q5
• PINPOINT TEST Q6
• START-UP PROCEDURE