211-00-1

Steering System

211-00-1

REMOVAL AND INSTALLATION

Power Steering Pump 4.0L SOHC
Special Tool(s)
Installer Set, Teflon Seal
211-D027 (D90P-3517-A) or
equivalent

CAUTION: While 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.

With the vehicle in NEUTRAL, position the

vehicle on a hoist. For additional information,
refer to Section 100-00.

2.

Remove the parts in the order indicated in the

following illustration and table.

To remove individual parts, only carry out the

listed steps:
Part

Steps

Power steering pump

4-5, 11, 15-21

Power steering pump

pulley

15-16

Power steering fluid

reservoir

1-6

Power steering fluid

cooler

7, 9-10

Steering gear-to-cooler
line

7, 8, 12, 14

Fluid cooler-to-reservoir
hose

2, 3, 7

Reservoir-to-pump hose

4-5

Pressure line

11-18

Copyright 2002, Ford Motor Company

Last updated: 7/5/2005

2003 Explorer/Mountaineer, 9/2002

211-00-2

Steering System

211-00-2

REMOVAL AND INSTALLATION (Continued)

Item

Part Number

Description
Fluid reservoir bolts

2
3

W611101-S/
W500213-S
W525923-S

4
5

W525923-S

6
7

3A697
W525923-S

(Continued)

Hose clamp
Fluid cooler-to-reservoir hose
(part of 3A697)
Clamps
Reservoir-to-pump hose (part
of 3A697)
Power steering fluid reservoir
Clamps

Item
8
9
10
11

Part Number

12

N606676-S
3D746
N606676-S/
W701834-S
W520413-S

13
14

3A719
3F886

Description
Steering gear-to-cooler line
(part of 3D746)
Cooler-to-crossmember bolts
Power steering fluid cooler
Pressure line retainer bracket
bolts
Clamp plate-to-steering gear
nut
Pressure line
O-ring (2 required)

(Continued)

2003 Explorer/Mountaineer, 9/2002

211-00-3

Steering System

211-00-3

REMOVAL AND INSTALLATION (Continued)

Item
15

Part Number
W605784-S309

16
17

3A733

18

3F886

19

W500213-S

20
21

W7008839-S
3A674

Description
Pulley bolts
Removal Note
Pulley
Pressure line-to-pump fitting
(part of 3A719)
O-ring
Installation Note
Reservoir bracket bolts
(loosen only)
Pump bolts
Power steering pump

3.

To install, reverse the removal procedure.

4.

Fill and leak test the system. For additional

information, refer to Power Steering System
Filling in this section.

Item 18: O-Ring Installation Note

1.

Using the special tool, install a new Teflon

seal on the pressure line fitting.

Item 15: Pulley Bolts Removal Note

1.

Loosen the bolts, rotate the tensioner clockwise

and remove the belt from the power steering
pump pulley, and then remove the bolts.

2003 Explorer/Mountaineer, 9/2002