• HEADINGS
  • DESCRIPTION
  • TESTING
    • PRESSURE TEST
      • Pre-Test Preparation
      • Pressure Testing
  • LUBRICATION
    • FLUID TYPE
    • FLUID LEVEL CHECK
    • HYDRAULIC SYSTEM BLEEDING
  • ADJUSTMENTS
    • BELT ADJUSTMENT
  • REMOVAL & INSTALLATION
    • DUST BOOTS & TIE RODS
      • Removal & Installation
    • POWER STEERING PUMP & PULLEY
      • Removal & Installation (4.0L)
      • Removal & Installation (4.0L SOHC)
      • Removal & Installation (5.0L)
    • POWER RACK & PINION STEERING GEAR
      • Removal (1996)
      • Installation
      • Removal (1997 - 4.0L)
      • Installation
      • Removal (1997 - 5.0L)
      • Installation
  • OVERHAUL
    • POWER STEERING PUMP
    • POWER RACK & PINION STEERING GEAR
  • TORQUE SPECIFICATIONS
• FIGURES
  • Fig. 1: Identifying Power Rack & Pinion Steering Components
• TABLES
  • BELT ADJUSTMENT
  • TORQUE SPECIFICATIONS

1996-97 STEERING

Power Rack & Pinion - Explorer & Mountaineer

DESCRIPTION

Power steering is a hydraulic-assisted rack and pinion unit with internal valving to direct fluid flow. The power steering pump is a vane type pump. Output pressure is regulated by a control valve located in pump housing. See Fig. 1 .

Fig. 1: Identifying Power Rack & Pinion Steering Components
Courtesy of FORD MOTOR CO.

TESTING

PRESSURE TEST

Pre-Test Preparation

1. With belt tension correct, disconnect power steering pump pressure hose. Keep hose end raised to prevent fluid loss. Connect Power Steering Analyzer (014-00207) to power steering pump high pressure hose with Power Steering Analyzer Fittings (014-0208). Connect other hose from valve side of analyzer to steering gear inlet.
2. Open valve on power steering analyzer. Run engine until fluid reaches normal operating temperature of 122-140°F (50-60°C). Check fluid level. Add fluid as necessary. Ensure all air is removed from fluid.

Pressure Testing

NOTE:

DO NOT hold steering wheel against stop or close shutoff valve for more than 15 seconds. Damage to steering system could result.

1. Increase engine speed to 1000-1500 RPM, close shutoff valve on power steering analyzer and check pressure. If fluid pressure is 1300-1480 psi (91.4-104.1 kg/cm² ), go to next step. If fluid pressure is below specification, replace power steering pump. If pressure is too high, check for kinked hose and repair. If fluid pressure exceeds standard pressure replace steering flow control valve.
2. Increase engine speed from idle to 2500 RPM. If flow exceeds 2.6 gallons (9.8L) per minute at 1500 RPM, replace pump. Leave valve on analyzer open and increase engine speed to 1000-1500 RPM. Check pressure at steering rack while turning steering wheel fully left and right. Pressure reading in stop position should be 1300-1480 psi (91.4-104.1 kg/cm² ). If pressure is below specification, replace steering rack.
3. Turn engine off. Remove power steering analyzer and reconnect all fittings. Fill and bleed hydraulic system. Tighten bolts to specification. See TORQUE SPECIFICATIONS table.

LUBRICATION

FLUID TYPE

Use Ford MERCON Fluid.

FLUID LEVEL CHECK

Fill the reservoir to minimum mark. Run engine until normal operating temperature is reached. Turn steering fully left and right about 10 times. Turn engine off with wheels in straight-ahead position. Check fluid level in reservoir, add as necessary.

HYDRAULIC SYSTEM BLEEDING

1. Fill reservoir to specified level. Run engine until power steering fluid reaches normal operating temperature, about 165-175°F (74-79°C). Recheck fluid level in reservoir and top off as necessary. With engine running, eliminate trapped air in system by turning steering wheel from lock-to-lock until fluid level no longer decreases and no bubbles exist in reservoir.
2. DO NOT hold steering wheel against lock (in far left or far right position). This action will create extremely high pressure and damage pump. Recheck fluid level in reservoir and top off as necessary. If excessive noise (whine) continues after bleeding procedure, the use of an air evacuator can reduce aeration of fluid.
3. An evacuator can be fabricated with a No. 11 rubber stopper with a 1/4" (6 mm) diameter hole drilled in center of stopper. Push a short length of rigid 1/4-5/16" tubing into hole in stopper. Attach a suitable length of vacuum hose to tubing.
4. Connect vacuum hose to vacuum source (an A/C vacuum pump is suggested). Do not use engine vacuum. Ensure fluid level is at least 1" (25 mm) below stopper. Start engine and let it idle approximately 15 minutes. Turn steering wheel every 5 minutes to aid in removal of air. Remove stopper, check fluid level and replace filler cap.

ADJUSTMENTS

BELT ADJUSTMENT

NOTE:

For proper serpentine belt routing, see appropriate ENGINE COOLING article.

BELT ADJUSTMENT

Application	New Belt: Lbs. (kg)	(1) Used Belt: Lbs. (kg)
All Models (2)	(3) 94 (43)	(3) 94 (43)
(1) Any belt operated for 10 minutes. (2) Tension is correct if tensioner is within indicator marks. (3) Minimum belt tension.

REMOVAL & INSTALLATION

WARNING:

Vehicles equipped with Air Suspension System must have system disabled prior to lifting or towing. To disable system, turn air suspension switch off. Switch is located in left rear of luggage compartment, in jack stowage area.

CAUTION:

When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.

DUST BOOTS & TIE RODS

Removal & Installation

1. Raise and support vehicle. Remove front wheels. Remove cotter pin and castle nut from tie rod end stud. Using Tie Rod End Separator (T85M-3395-A), separate tie rod end from steering knuckle. Paint an alignment mark on tie rod end and tie rod. Loosen jam nut. Unscrew tie rod end, counting number of turns to remove.
2. Remove dust boot clamps. Remove dust boot. Turn steering wheel in direction of tie rod end being removed to expose flat at end of steering rack. Using a wrench to prevent steering rack from turning, unscrew inner end of tie rod from steering rack. To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS table. Check alignment.

POWER STEERING PUMP & PULLEY

Removal & Installation (4.0L)

Remove drive belt. Remove hose connections from pump and let fluid drain into drain pan. Remove fan. Remove power steering pump pulley using Puller (3A733). Remove 3 front pump mounting bolts. Remove pump from vehicle. To install, reverse removal procedure. Fill and bleed hydraulic system. Tighten bolts to specification. See TORQUE SPECIFICATIONS table.

Removal & Installation (4.0L SOHC)

Remove fan. Loosen power steering pump pulley bolts. Remove drive belt. Remove pulley. Remove hose connections from pump and let fluid drain into drain pan. Remove 3 front pump mounting bolts. Remove pump from vehicle. To install, reverse removal procedure. Fill and bleed hydraulic system. Tighten bolts to specification. See TORQUE SPECIFICATIONS table.

Removal & Installation (5.0L)

Remove drive belt. Remove hose connections from pump and let fluid drain into drain pan. Remove 3 front pump mounting bolts. Remove rear mounting bolt. Remove pump from vehicle. To install, reverse removal procedure. Fill and bleed hydraulic system. Tighten bolts to specification. See TORQUE SPECIFICATIONS table.

POWER RACK & PINION STEERING GEAR

Removal (1996)

1. Start engine. Rotate steering wheel from lock-to-lock (entire gear travel). Record number of rotations. Divide the number of rotations by two. This gives the required number of turns to place system in the on-center position. Verify the front wheels and steering wheel are in the straight-ahead position. From the lock position, rotate steering wheel the number of turns determined in procedure. This places the gear in the on-center position.

NOTE:

DO NOT rotate steering column when intermediate shaft is disconnected or damage to clockspring will result.

2. Remove bolt retaining the lower steering column shaft to the steering gear input shaft. Disconnect the lower steering column shaft from the steering gear.
3. Remove stabilizer bar attachment from frame for clearance to remove gear. Unscrew the quick connect fittings for the power steering pressure hose and power steering return hoses at the steering gear housing. Plug ends of fluid lines removed and ports in gear to prevent damage and entry of dirt.
4. Remove 2 nuts from P/S cooler. Remove P/S cooler from vehicle. Remove and discard the cotter pin retaining the nut to tie rod end and remove nut. Separate tie rod ends from front wheel spindle using Pitman Arm Puller (T64P-3590-F).
5. Remove the 2 nuts, bolts, and washer assemblies retaining steering gear to front crossmember. Remove steering gear from vehicle. If required, remove steering gear mounting bracket housing insulators and steering gear insulators from steering gear housing.

Installation

1. If removed, install steering gear mounting insulators into the steering gear housing. Push the steering gear mounting insulator and steering gear insulator in until there is no space between the lip on the insulator and steering gear housing. Position steering gear on front crossmember. Install nuts, bolts and washers retaining steering gear to front crossmember. Tighten bolts to specification. See TORQUE SPECIFICATIONS table.
2. Position power steering cooler onto bolts and install nuts. Tighten bolts to specification. See TORQUE SPECIFICATIONS table. The fittings design allows the power steering pressure hose and power steering return hose to swivel when properly tightened. Do not attempt to eliminate looseness by overtightening, since this can cause damage to fittings. Connect power steering pressure hose and power steering return hose to appropriate ports on steering gear housing. Tighten bolts to specification. See TORQUE SPECIFICATIONS table.
3. Make sure the tie rod ends are seated in the tapered spindle holes to prevent rotation while tightening nut. With the steering gear, steering wheel and wheel in the on-center position, attach the tie rod end to front wheel spindle. Tighten bolts to specification. See TORQUE SPECIFICATIONS table. If necessary, advance tie rod nuts to the next slot. Install cotter pins.
4. Verify that no rotation from the on-center position has occurred. Position steering column lower intermediate shaft over steering gear input shaft. Outer input shaft dust shield must be in place. Replace pinch bolt Tighten bolts to specification. See TORQUE SPECIFICATIONS table. Replace the front wheel and tire assemblies. Replace wheel covers. Lower vehicle.
5. Refill power steering oil reservoir with Premium Power Steering Fluid (E6AZ-19582-AA). Purge air from steering system. See HYDRAULIC SYSTEM BLEEDING under LUBRICATION. Verify absence of any unusual power steering noise.
6. Check and adjust toe alignment specifications. See appropriate WHEEL ALIGNMENT article under SUSPENSION. Make sure steering gear operates correctly and is not leaking. Check and adjust fluid level in power steering oil reservoir.

Removal (1997 - 4.0L)

1. Disconnect the battery ground cable. Remove the air cleaner outlet tube. The fan shroud cannot be removed without removing the fan blade. Use Fan Clutch Wrench (T96T-6312-A) and Fan Hub Wrench (T96T-6312-B). Wrench to loosen and remove the fan blade. Remove the fan shroud bolts. Lift the fan shroud out of the lower retaining clips. Lift the fan shroud and the fan blade and clutch assembly together and remove from vehicle.

CAUTION:

Do not use heat to loosen a seized lug nut. Heat can damage the wheel and the wheel bearings.

2. Remove the center cap from the front wheel and tire assemblies. With the weight of the vehicle on the tires, loosen, but do not remove, the lug nuts.

WARNING:

The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations.

3. Raise and support the vehicle. Remove the lug nuts. Remove the front wheel and tire assemblies.
4. Remove the radiator deflector bolts and remove the radiator air deflector. Loosen the left tie rod end jam nut. Disconnect the tie rod ends. Remove and discard the cotter pins. Remove the castellated nuts. Disconnect the tie rod ends from the steering knuckles. Remove the left tie rod end. Count and record the number of turns required to remove the tie rod end.
5. Remove the front stabilizer bar link nut. Remove the front stabilizer bar link bolt. Remove the front stabilizer bar spacer. Repeat for the other side. Remove the four (two each side) stabilizer bar bracket bolts. Remove the stabilizer bar.
6. Remove the power steering fluid cooler nuts and remove the power steering fluid cooler. Separate the power steering fluid return line hose from the power steering fluid cooler. Allow the system to drain. Disconnect the power steering return hose. Remove the power steering fluid cooler. Remove the power steering pressure hose. Remove the power steering return hose.

CAUTION:

Do not rotate the steering wheel when the lower steering column shaft is disconnected or damage to the air bag sliding contact will result.

7. Remove the lower steering column pinch bolt and disconnect the intermediate shaft from the steering gear input shaft.

CAUTION:

Hold the tops of the steering gear to crossmember stud bolts to avoid damaging the steering gear fluid transfer tubes.

8. Remove the steering gear mounting nuts. Remove the steering gear mounting stud bolts. Remove the steering gear to cross member insulator bushings. Rotate the steering gear control valve housing toward the front of the vehicle. Remove the power steering pressure valve.
9. Turn the steering gear input shaft to the right until the stop is reached. Move the steering gear as far to the right side of the vehicle as possible. Move the left front wheel spindle tie rod forward to clear the frame cross member. Remove the steering gear from the vehicle.

Installation

NOTE:

Make sure the steering gear control valve housing is turned toward the front of the vehicle.

1. Install the steering gear into the right opening of the cross member. Turn the steering gear input shaft to the right until the stop is reached. Move the steering gear as far to the right side of the vehicle as possible. Move the left front wheel spindle tie rod into the opening in the cross member and move the steering gear into position.
2. Install the steering gear to cross member insulator bushings. Install the stud bolts. Hold the tops of the steering gear to crossmember stud bolts to avoid damaging the steering gear fluid transfer tubes. Install the nuts.

CAUTION:

Do not rotate the steering wheel when the lower steering column shaft is disconnected or damage to the air bag sliding contact will result.

3. Connect the intermediate shaft to the steering gear input shaft and install the lower steering column pinch bolt.
4. Make sure the small hole is up. Install the power steering pressure valve. Replace the Teflon(R) seals on the power steering return line tube nut and on the power steering pressure line tube nut. Install the power steering return hose and then tighten tube nut. Install the power steering pressure hose and tighten the tube nut.
5. To install the power steering fluid cooler, connect the power steering return line hose. Connect the power steering return hose. Position the power steering fluid cooler and install the nuts.
6. Install the front stabilizer bar. To install, reverse removal procedure.
7. Install the left tie rod end on the front wheel spindle tie rod. Rotate the tie rod end the number of turns recorded during removal. Connect the tie rod ends to the steering knuckles. Position the tie rod ends on the steering knuckles. Install the castellated nuts. Install the new cotter pins. Tighten the jam nut.
8. To install the radiator air deflector, position the radiator air deflector and install the bolts.
9. To install the front wheel and tire assemblies, position the front wheel and tire assemblies. Install the lug nuts and lower the vehicle. Tighten the lug nuts. See TORQUE SPECIFICATIONS table. Install the center caps.
10. Install the engine cooling fan. To install, reverse removal procedure.

NOTE:

When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy.

11. Connect the battery ground cable.
12. Fill the power steering system with Motorcraft MERCON(R) ATF meeting Ford specification MERCON(R). Perform air purge with external source; refer to the procedure in this section. See HYDRAULIC SYSTEM BLEEDING under LUBRICATION.
13. If equipped with air suspension, reactivate the system by turning on the air suspension switch. Align the vehicle. See appropriate WHEEL ALIGNMENT article under SUSPENSION.

Removal (1997 - 5.0L)

CAUTION:

Do not use heat to loosen a seized lug nut. Heat can damage the wheel and the wheel bearings.

1. Remove the center cap from the front wheel and tire assemblies. With the weight of the vehicle on the tires, loosen, but do not remove, the lug nuts.
2. The fan shroud cannot be removed without removing the fan blade. Use Fan Clutch Wrench (T96T-6312-A) and Fan Hub Wrench (T96T-6312-B). Wrench to loosen and remove the fan blade. Remove the fan shroud bolts. Lift the fan shroud out of the lower retaining clips. Lift the fan shroud and the fan blade and clutch assembly together and remove from vehicle. Disconnect the battery ground cable.

WARNING:

The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations.

3. Raise and support the vehicle. Remove the lug nuts. Remove the front wheel and tire assemblies. Remove the inner fender rubber flaps.
4. Remove the top motor mount nuts. Remove the radiator air deflector to frame bolts and the radiator air deflector. Drain the engine coolant from the radiator.
5. Loosen the jam nuts on the tie rod ends. Remove and discard the cotter pins. Remove the castellated nuts. Separate the tie rod ends from the steering knuckles. Remove the left tie rod end. Count and record the number of turns required to remove the left tie rod end.
6. Remove the front stabilizer bar link nut. Remove the front stabilizer bar link bolt. Remove the front stabilizer bar spacer. Repeat for the other side. Remove the four (two each side) stabilizer bar bracket bolts. Remove the stabilizer bar.
7. Remove the oil filter. Disconnect the lower radiator hose from the oil cooler. Remove the oil cooler bolt and the oil cooler bolt "O" ring. Remove the oil cooler and the oil cooler "O" ring. Disconnect the oil cooler from the water inlet hose. Clean and inspect the surfaces of the cylinder block and the oil cooler.
8. Raise the engine. Position a block of wood between a screw jack and the bottom of the oil pan to avoid damaging the oil pan while raising the engine.
9. Disconnect the power steering return line hose at the power steering fluid cooler. Drain the power steering fluid from the system. Remove the power steering fluid cooler to crossmember nuts. Disconnect the power steering return hose at the power steering fluid cooler and allow the fluid to drain. Remove the power steering fluid cooler.
10. Unscrew the nut and remove the power steering pressure hose. Unscrew the nut and remove the power steering return hose.

CAUTION:

Do not rotate the steering wheel when the lower steering column shaft is disconnected or damage to the air bag sliding contact will result.

11. Remove the lower steering column pinch bolt and disconnect the intermediate shaft from the steering gear input shaft.

CAUTION:

Hold the tops of the steering gear to crossmember stud bolts to avoid damaging the steering gear fluid transfer tube.

12. Remove the steering gear to crossmember stud bolts and nuts. Remove the steering gear to crossmember insulator bushings.
13. Rotate the steering gear control valve housing toward the front of the vehicle. Remove the pressure valve. Turn the steering gear input shaft to the right side until the stop is reached. Move the steering gear as far to the right side of the vehicle as possible. Move the left front wheel spindle tie rod forward to clear the crossmember and turn the steering gear input shaft to the left side until the stop is reached. Remove the steering gear from the vehicle.

Installation

1. Make sure the steering gear control valve housing is turned toward the front of the vehicle. Install the steering gear into the right opening of the crossmember. Turn the steering gear input shaft to the right side until the stop is reached. Move the steering gear as far to the right side of the vehicle as possible. Move the left front wheel spindle tie rod into the opening in the crossmember and move the steering gear into position.
2. Rotate the steering gear control valve housing toward the rear of the vehicle. Make sure the small hole is up. Install the pressure valve. Install the steering gear to crossmember insulator bushings.
3. Hold the tops of the steering gear to crossmember studs to avoid damaging the steering gear air transfer tube. Install the steering gear to crossmember stud bolts and nuts.

CAUTION:

Do not rotate the steering wheel when the lower steering column shaft is disconnected or damage to the clock spring will result.

4. Connect the intermediate shaft to the steering gear input shaft and install the lower steering column pinch bolt.
5. Replace the Teflon(R) seals on the power steering return line tube nut and on the power steering pressure line tube nut. Install the power steering return hose and tighten the tube nut. Install the power steering pressure hose and tighten the tube nut.
6. Connect the power steering return hose to the power steering fluid cooler. Position the power steering fluid cooler and install the power steering fluid cooler to crossmember nuts. Connect the power steering return line hose to the power steering fluid cooler. Lower the engine.
7. Connect the oil cooler to the water inlet hose. Position the oil cooler "O" ring and install the oil cooler. Be sure to position the oil cooler bolt "O" ring into the groove on the oil cooler. Failure to properly position the "O" ring may crush the "O" ring and cause an engine oil leak. Coat the "O" ring with petroleum jelly to hold the "O" ring in place during oil cooler bolt installation. Install the oil cooler bolt and oil cooler bolt "O" ring. Tighten the oil cooler bolt. Connect the lower radiator hose to the oil cooler. Install the oil bypass filter. Coat oil filter gasket with motor oil.
8. Install the front stabilizer bar. To install, reverse removal procedure.
9. Install the tie rod end. Rotate the tie rod end the number of turns recorded during removal. Connect the tie rod ends to the steering knuckles. Position the tie rod ends to the steering knuckles. Install the castellated nuts. Install the new cotter pins. Tighten the jam nuts.
10. Install the radiator air deflector. Install the top engine mount nuts. Install the inner fender splash shields.
11. Install the front wheel and tire assemblies. Position the front wheel and tire assemblies. Install the lug nuts and lower the vehicle. Tighten the lug nuts. Install the center caps. Install the engine cooling fan. To install, reverse removal procedure.

NOTE:

When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy.

12. Connect the battery ground cable.
13. Fill the power steering system with Motorcraft MERCON(R) ATF. Perform air purge with external source. See HYDRAULIC SYSTEM BLEEDING under LUBRICATION. If equipped with air suspension, reactivate the system by turning on the air suspension switch.
14. Refill and bleed the engine cooling system. Start the engine and run for two minutes. Stop the engine and allow the oil to drain back into the pan. Check the oil level and add as required. The oil level should read between the MIN and MAX lines. Align the vehicle. See appropriate WHEEL ALIGNMENT article under SUSPENSION.

OVERHAUL

POWER STEERING PUMP

Overhaul of power steering pump is not recommended by manufacturer.

POWER RACK & PINION STEERING GEAR

Overhaul of steering gear is not recommended by manufacturer. Internal steering gear parts are not available from manufacturer.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Application		Ft. Lbs (N.m)
Castle Nut		56-76 (77-103)
Cooler Nuts		50-68 (68-92)
Engine Mount Bolt (5.0L)		95-125 (129-170)
High Pressure Hose Connection
4.0L		30-40 (41-54)
4.0L SOHC & 5.0L		40-54 (53-73)
Hose Connection Bolt		51-58 (69-78)
Inner Tie Rod Socket		81-95 (110-130)
Intermediate Shaft Pinch Bolt		30-41 (41-56)
Jam Nut		150-68 (68-92)
Junction Block/High Pressure Line		11-18 (15-25)
Lug Nuts		100 (135)
Pump Housing Bolt		11-15 (15-20)
Pump Pulley Nut		15-20 (21-28)
Radiator Air Deflector Bolt		18-22 (25-30)
Steering Rack Mounting Bolt		94-127 (128-172)
Tie Rod Adjusting Nut		50-68 (68-92)
INCH Lbs. (N.m)
Fluid Line Mount Bolts		18-26 (3-4)
Reservoir Mount Bolt		62-89 (7-10)