11-00-1 GROUP STEERING SYSTEM 11 SECTION TITLE PAGE ‘STEERING COLUMN. 11-001 STEERING COLUMN: 11-05-4 SECTION TITLE PAGE STEERING SYSTEM, POWER... 14024 STEERING SYSTEM—SERVICE.. 1100-41 SECTION 11-00 Steering System—Service SUBJECT PAGE DESCRIPTION. 14-00-41 DIAGNOSIS. "1100-6 SPECIAL SERVICE TOOLS . 1-00-13 ‘SPECIFICATIONS. 7 1-00-18 TESTING aliminary Tests, A002 Start-Up Procedure. VEHICLE APPLICATION . VEHICLE APPLICATION ‘Taurus/ Sable and Taurus SHO. DESCRIPTION The power steering pump has a service identification tag to identity assemblies for service purposes. The tagis located on reservoir body and contains. information as shown below. Power Steering Pump Mode! identification EXAMPLE MODEL YEAR MONTH SHIFT DAY Ga186-D 903 Tawee Sable July 198211-00-2 Steering Systom—Service 11-00-2 | nr ne EECCA DESCRIPTION (Continued) FORD PART NUMBER SERIAL ‘NUMBER vesh a DAY 1 ee Serx THROUGH: SHET wus SDAY Novy DeC.2 NIGHT PRODUCTION NUMBER (PER SHIFTIPER DAY) 3. Check hoses for cut O-rings. ‘Turning Effort Check Ensure front wheels are properly aligned and tire [ressure is correct before checking turning effort. 1. Park vehicle on dry concrete and set parking brake. 2, Idle engine for two to three minutes. Turn steering Wheat to the left and right several times to warm fluid to 43-49°C (110-120°F), 8. With engine running, attach a pull scale to rim of steering wheel. Measure pull required to turn Wheel one complete revolution in each direction, Refer to Specifications at end of this Section for acceptable measurements. TESTING Preliminary Tests ‘Make the following preliminary tests before power steoring disassembly. Ale Bleeding \fbubbies are present in the power steering fluid, bleed the system as follows: 1. Filreservoir. 2. » Run engine untifuid reaches normal operating temperature of 74-79°C (165-175°F). CAUTION: Do not hold whee! in the far left or right position, or damage to power steering pump may result. 3. Tum steering wheel allthe way to the left nd right several times. 4. Check fluid evel. 5. airs stil trapped in system, refer to Purging Power Steering System of Alt. Fluid Level Check 41, Idle engine for two to three minutes. Turn steering wheel all the way to the let and right several times to warm fd to 43-49°C (110-120°F). CAUTION: Do not overfill reservolr. 2. Check fluid ievel in the power steering reservotr. Fiuid evel should be at the COLD FULL mark. I levelis low, add Premium Power Steering Fluid E6AZ-19582-AA (ESW-M2C3S-F) or equivalent. Pump Belt Check Replace and adjust broken, glazed or worn pump belts. Refer to Section 03-05 for adjustment Procedures. Fluid Leak Check 4. With engine idling, turn steering whee! iat to right several times. Check all possible leakage points. 2. Tighten ailloose fittings. Replace damaged ines and seals. Pump Flow and Pressure Test Before performing pump flow and preseure test, ‘complete the following checks for conditions which ‘could cause loss of power assist. Take corrective ‘action if necessary. ‘Check pump reservoir for proper fluid level. ‘Check tires for correct air pressure. ‘Check pump belt for proper tension. ‘Check pump for correct model and vehicle application. &. Check for correct size pulleys on pump and engine, 6. Check entire system for damage. Replace parts, ifnecessary. Ifthe above items are correct, or have been corrected, and the loss of assist stil exists, test power steering pump flow and pressure to determine whether the trouble isin the pump, power steering gear or hoses. Test Equipment 1. Engine tachometer. 2. Thermometer: -17.8° to 148.9°C (0° to 300°F) 3. Rotunda Power Steering System Analyzer 014-0207 or equivaiont. 4. Sot of adapter fitings. ‘The test procedure used in conjunction with the Rotunda Power Steering System Analyzer or ‘equivalent provides a method for checking the complete power steering sysiom. This analyzer can be used to determine the cause of hard steering ‘and/or lack of assist concerns, ‘The analyzer provides readouts for the following: © System Back Pressure © Pump Flow © Steering Gear internal Leakage © Pump Roliof Pressure PEes 7690 Taurue/ Sable July, 199211-00-38, Telntapretston ofthe shove readouts wil determine Test Procadure \which of the folowing conditions or components are vipower etoaring ti sof which of the fof]owing co 1 Lgensower storing ne bracket rar of «@ Restriction in Hoses or Fitings 2 Disconnect he ig pressroom he pump ‘and connect into the appropriate hose adapter ele ee of the analyzer. For Taurus SHO, iting © nafficient Pump Cam Pack 014:00208 or equivalent © Sticking Rei! Valve 8. Tivead the other analyzer adapter into pump. On © Binding in Suspension ‘Taurus SHO, thread the edaptor into the steering sear. 4, Connect anelyzer hoses to adapters. Tighten both connections to 20 Nem (16 lb-) maximurn. ‘Tourus/Sable ROTUNDA Power STEERING ‘SYSTEMANALYZER, o1a.0c207 STEERING GEAR S508 RETURN LINE ASS SATO PRESSURE LINE ASSY Sania oas7 7908 Tavroe/ Sabie uy, 1092TESTING (Continued) Stooring Systom—Service 11-00-4 ‘Taurus SHO Part Htem | _Number__| Description + | aR700 Power Steering Reservoir 2|— Pragsure Hose From Pump 3 ]o1400207 | Rotunda Power Steering System Analyzer 4 | sore Cooler Assy 6 | 3r731 Hose Assy 6 [aari9 Hose Assy 7 | sasra Power Stearing Pump Assy 5. Add power steering fluid to the pump, on ‘Taurus /Sable or reservoir on Taurus SHO if required. Start the engine and run it for approximately two minutes at ide. 6. Record the following: @. Flow: iters/ arin (gallons/min) at 78° + 2°C (172? 45°F), b. Pressure: kPa (psi) at 78° 2°C (172° 45°F) atidie withthe gate valve fully open. © I flows below 5.7 fters /min (1.5 gallons min), Taurus/‘Sable, or 8.3 liters min (2.2 gallons /min) Taurus SHO, ‘the pump may require service. Howaver, at this point, continue the diagnosis. Check flow and relief pressure against the model ‘Bump being tested. © If pressure is above 1034 kPa (150 pei), ‘check hoses for restrictions, 10. Ts Partially close the gate valve to build up §100 kPa (740 psi). Observe and record flow, Morin (alone mat 78° & 2°C (472° ty IE fiow drops toa levellower than the valve, disassemble the pump and replace the cam pack. ithe pressure plates are cracked or worn, replace then. Continue with diagnosis. On Taurus SHO, it flow drops toa level lower than 3.4 liters /min (6.9 gallons /min) replace pump. ‘Completely close and partaly open gate valve three times. (Do not alow valve to romain closed {or more than five seconds.) Observe and record pressure, kPa (psi) Refer to the chart for pressure specification for the applicable pump model and vehicle ‘pplication. pressure recorded is lower than ‘minimum spectication, replace flow control valve inthe pump used on Taurus Sable. On Taurus ‘SHO, replace pump. Ifthe pressure recordedis above maximum spectication listed, the flow control valve inthe pump should be rernoved and cleaned or replaced on Taurus / Sabo. On Taurus SHO, the ump should be removed and cleaned or replaced. {ncrease engine speed from idle to approximately +1500 rpm. Observe and record flow, lara min (Gallons rin). It flow exceeds the maximum free flow specified, the flow control valve in the pump on Taurus/ Sable should be removed and cleaned or replaced. On Taurus SHO, the pump should be removed and cleaned or replaced. CCheckile speed, and set f necessary. With the engine atic, tur (or have an assistant turn) steering wheel to the left and ight stops. lecord pressure and flow at stops. Pressure developed at both stops should be nearly the same @s maximum pump output pressure Atthe samo time, flow should drop below 1.9, ‘ters min (0.5 geon/min). tthe pressure does ‘not reach maximum output or the fow does not towposi + Faareginaen eae Rortatie nina este eregemecnetree | [eis teseteattiae Wore Decsredanig tain |Z ecearangar men” | Sarttermaperten arack-and-pinion steering system ‘Hos striction. @ Clean end replace as necessary. should not be misdiagnosed as@ = /@ Pump pulley loose /warped. © Replace pulley. Refer to Section ERUSSNTAETEN os |* Retetateaet i oi eeoameree reece |e ee ate oo, maa eee Section 11-02. ae ereaelles ren atte ioeecenarena ae ae Section 11-02, 1009 Tawros Sable ly, 198211-009 11-009 DIAGNOSIS (Continued) STEERING SYSTEM OINGHOSIS Contin) couDITION POSSIBLE SOURCE ‘AGTION 7 Taw Eas et hvohco Speeds [APB ystonmaitnton, 7 Hetero VAP yaton diagnosis Procedure ealcanice or obace SSrmpanensacorseoy 3 Law Seeing Gea Bara aoe | VAPSavaTommatncion . 30mph | © Eira Coraae + Ta aves acairenduor | Toten air bot. Psi6 rien as NOTE: Clean Offthe Steering Gear © Leaks between actuator ant © Tighten actuator bolts. Mo. Catoclneanv Sane” |° ekabmimean ectutorand ht acuntorbo Gear External Leakage Checks. ®@ Replace two upper actuator seals. © earttingsoce,crosstnvendea | Rapectandigtonorrepace ser tipped tony. « oRPESR tena gearsen |e Bopice oar acconoy argon on otha ack teu @ Tau crackadortenkng veto |e Replace ger aeerdiy ee NOTE: The only serviceable SSrponete ok Ra AES stoonag | Sear aro th bots, roa eter ang atutor bl and 022i Stale Cenmstbn semeesty tntenng rihina re tobscerscosby | lesan arte sosomby anh sen, 3 Taoaw nConer 7 Sienna gwarmotnabolo > Tahara tae ce Wotton Rear Secon NOTE: Thconaionshowae | 1° porate eeecaee! SSuckegonGenter One" | @ columitemedat shan «Taken Rtero Secon 1104 Loose Condition Gan be ott loose. | : meme glcaded | Releco bot csoreiened! | 2 eerste anor gone Toiten | ease eu oder aoe ich gsr estes + SSamumedstosnaioins |e Replace omedas tat coarse see ee Secon 1-04, © Replace as required, ing or broken. esis «Palace as route. setae ror Fea ies. Whee eres 3 nepscesetaates Rls ssetiraas Lose wien «Feet Rart sects. | + Sasng Wreanor Gane Je peat sting © oi erie sectoror0 Ropar 2 Beep omp ote Resection she maa NOTE: Groove on Steel Hub of © Pinion installed in rack off location. ° .ce gear assembly, Refer to Semiptineuienbeitine Beatse pgzansonty ‘Shaft With Front Wheels in eee : a ‘Straight Ahead Position to Line Up | @ ing gear loose on frame. |® Tighten. Refer to Section 11-02. ‘Steering Wheel Spokes Properly. | Column intermediate shaft © Index shatt to correct position. ‘Steering Whee! Centerline Should Be Wilhin 10 Degrees of Vertical Plane After Too-inis Adjusted. ‘olf opation in column 7909 Tauros/Sablo uy, 105211-00-10 11-00-10 ae DIAGNOSIS (Continued) ‘STEERING SYSTEM DIAGNOSIS (Continued) CONDON POSSIBLE SOURCE ACTION 3 Snaotiness Sticky © Loose orwom pulley bok Tahion ot replace. Refervo Fealing-~Condtion of Momentary Section 0-06, Build Up itch, Lump ortiestation | © Frontlower control arm bal joint Replace front iower contol arm in Steering ttrta,Ueualy wor Sseombiy Rolorto Section 0401 GceuringJustasine Tunis | © Calum tim rubbing steering Reposition inm on column Begun. thay GccurRightorLen, | whee! fandinRare Geses, Oesuringein’ |e Sincingin gear contol valve Replace ges | Birections: tay be Noticed aseombly. Section 1-02" | During Parking, Cow Speed Turns © Wateror ci on pulley be. Sinan orroplacs | GratRoue Speede tris, © Column misaligned or binging. Sign courin assembly, Reterto Gondtion is etected During Section roa Parking Maneuvers, itMay Atsobe |© Flex coupling dstorted or Aionor replace as required Noticed Ding Higher Spe fractures, Brveg © Hexhousingrepbing against ‘ign or reposition flex coupling. housing fave NOTE: Discolored Steering Fluid in | Column intermediate shatt joints Replace as required. Rack-and inion Szering System’ |° o¢q|womoroindng " * woul se Misdiagnosed 28 @ | @ Column intermediate shat mn. Functional o Noise Concern. i syle 7 es . 30, shack absorbers 0, adust or replace a8 rings. Column shaft clips missing or amaged. Steering gesr retaining bolts loose or damaged. ‘Whee! bearing loose or worn. ‘Loose whee! ug nuts. lemproper front end alignment. necessary. Lubricate or replace aa required, Service as required. Tighten. Replace as required. Reterto Section 04-01 Tighten. Refer to Section 04-04. Replace gear assembly. Inflate, Align front end, Refer to Section 4-04. 1900 Taurue/ Sable duly, 186214-00-11 11-00-11 DIAGNOSIS (Continued) STEERING SYSTEM DIAGNOSIS (Continued) ‘CONDITION POSSIBLE SOURCE ‘ACTION © Uneven Drive Efforts, Pulls or Radiat tires ned bole). Raplace es necessary. Leads to One Side—Condilion Front orrear end misaligned. Allg. Recognizedby he OriverWnile | @ Steering gaar valve offorts, © Replace gear ascambly. Refer to Turning the Steering Whee! ina Unbalanced. tfors wil be lighter Section 11-02, | Lett or Right Tura. This Condition inane direction.) Wil Reveal Lighter Ettortein One | © Front suspension components © Replace as required. Refer to Direction, Very Noticeable tothe | damaged. Section 04-04 Driver Vehicle Pulls orLeadsto [© Lowiirepressure orincorrect tront | Check pressure and One side. rect tr size or incorrect ° © Check front and rear brakes for ° Side on a Reasonably Flat Road. lt | proper operation. May orMayNotbe Accompanied |@ Check orbentrear axle housing | © DyUnequalEtfort Requirements at |” and for damaged or sagging the Steering Wheel pings inthe ont orrear ‘suspension. NOTE:Peform the Foliowing Test |» Encex sear suspension ortooseor |e foDetermine tConcernisfelated |° ors s creme to Steering Gear or Vehicle System. ‘At 16:66 mph on aflat straight |® Vehicle uneveniy ioaded. Correct as required. eee en teeiarn: [© Front or rear whee! bearing loose Rofer to Sections 04-01 or 04-02. ling, place shift eelector in gr worn, © Steering gearretaining boltsloose | @ Tighten. NEUinAL pootionandtumot |® Stesrna es “ignition Ithe vehicle continu aqiouiineventaccrninues's |, Siam Stiamdortindes, | Algncoumn anand loratithe same decom |S ey ato erst ‘isnot the cause. If ‘Section 06-04. Rete de toes eaipate tout tale | ring gear concern } wines ase ctea ‘This condition | anced steering ge | ti | ‘© Poor Retumability is @ Condition | © Column irim rubbing steering "@ Reposition trim ring in column 1 Noticed Wnen tha Vehicle Fallsto | wheel assembly sits, | Return to a Nearly Stre | © Front lower control arms worn. © Replace lower control arms. Refer | seuiataeet Comet anenes | weet | Ferner wer |e exuntodorbudguppercint | Hopes are eset Boes tne feta Feereeeeel te, |g BekBiodandlorieodendbat |e Replace torosad/orterd venenatis Cotte May |° pi seme rer Reena emeereM |, Setinavavesseenbyon |» Ropce gar ansenoy-Reto'o SivrononeShosion Stee Cisne ftinone |* Seite #8 NOTE: Th Conon acto nto AcconpmiesByavionenay |e [ahlaterSttendaignnant. |e Algnontens Build Up, Hitch, Lump, or © Steering linkage, shock ° aoe ntante terete |p emeainace. mooie Veena | shee cere tarma” | * igtimnoarea situated by Sr Sei! Sate Srna Maneuvers. ‘© Intormediate column shatt joints «|e Replace intermediate shatt soon’ \° sche «BENS samaceccrosomenbar, |e Bapecoaegocossas etorto sera 3S «catenin deg « Eapcteasreonay So Eng mien sear © Lowtire pressure or incorrect |e Check pressure ana pressure front to rear. | inflate/deflate as necessary. ¢ Steering wheel clear vision off |e Adjust as required, ‘ovation | © Incorrect tie size or incorrect |e Replace as required ‘ype. I "1989 Taurus) Sabie uy, 198211-00-12 Steering System—Service 41-00-12 DIAGNOSIS (Continued) STEERING SYSTEM DIAGNOSIS (Continued) ‘CONDITION POSSIBLE SOURCE ‘ACTION @ Nolee/ Rattle Chvokie Cloke? Pops! Squeaks Creaks /Clunk/ ‘Squawk’ Hiss ‘here are Many Systom Noises Which Gan be Misglagnosed as riginating From the Power Steering Gear. Most System Consequently the Noise Pitch Garetul Diagnosis ie Necessary to Prevant Unnecessary Services, Disconnecting of Belts and Re-evaluation e Essential in Many Gases, asis Partially Cycling the Steering Wheal With the Engine in OFF: NOTE: A Common Noiee inthe Rack-and Pinion Steering Gears @ Hissing Sound. The Sound is Most Evigent at Stalic Position or During | Parking Maneuvers, There ie No Relationship Between this Noise | andPertormanee of the St | Miss" May Oceur at end of ‘Steering Whee! Travel or When Slowly Turning at Stand Stil, orate Particular Postion. Column intermediate shart ‘connecting bolt loose. Column im rubbing sieering wo Coose or worn pump bet. Front lower control arm worn or binding. Brinelled or binding upper strut ing. Flex coupling distort lox coupling clamp bolt ioose, Pump bracket loose or misaligned. Lack of ubricant where hora brush Contacts rub steering whee! plate Column shaft clips missing. Column U-jointstoose. {Loose tie rod ends or ball joins. Gear assembly loose on frame, Loose suspension struts. Flex coupling ractured. Loose whee! lug nue. Pressure hose grounded against fender or vacuum canister, Front wn Steering shat insulators cracked or er. inked pressure hoses. St Teak. Pulley loose or warped. ‘Asrated fi. Waterin steering tuid ring gear or pump external Tighten, Referto Section 11-04, Reposition trim on column, Adjust or replace as required. Rotor to Section 03-06. | Replace asrequired.Relerto | Section 04-01 Align flex coupling. Tighten. Retar to Section 11-04 Tighten and align. Feferto Section i102. Lubricate or adust as required Replace as required, ‘Adjust or replace as required. Replace as required Tighten. Refer to Section 04-04, Replace bearing, Refer to Section oso Correct as necessary Replace or lubricate as required Reposition pressure hoses. Refer to Section 11-02. Inspect and replace or service as required Replace pulley assembiy. Purge and evacuate sysiem. Purge and evacuate system. 1903 Taurus Sable dy, 108211-00-13 Steering System—Service 11-00-18 DIAGNOSIS (Continued) [STEERING SYSTEM DIAGNOSIS (Continued) (CONDITION POSSIBLE SOURCE ACTION ] © Wandering/Darting Painting ‘© Giosring gearreteining bolleloose [© Tighten, Refer to Section 19-02. "Condition Noticed When the Gar | or damages. igDrivonina Straight Ahead © Improper front or rear end © Align. Position With the Whool Holdin a | alignment. FimPosttion andthe Vehicle |@ Frontlower controlarmballjoint(s) | ® Replace as required. Refer to ‘Wanders to Either Si worn. Section 04-01 'stoDownthe Road Steering |@ Brinolied orbinding strut upper © Replace bearing itis Not Smooth and Seems Sticky andthe Driver Cannot | © © Correct aa required. (© Column trim ubbing steering ‘© Reposition trim on columa weet assembly. Loose suspension struts or bl © Adjust orrepiace as required. {plats binding. © Loose tierod ends. © Replace tie rod ends. NOTE: Pointing Characteristics |S Column te shatt oh Replace nt shat freNormalwinthe Column termediate shat oint Replace intermediata shat Flack-and-Pinion Steering System | @ Golumn misaligned or binding. © Align column assembly. Upto 10 Degrees OFt-Center. Geartierodioner alljoistooseor | @ Replace gear tie rods. | ‘© Column intermediate shaft ‘© Tighten. Refer to Section 11-04 connecting bolt loose. © Lowtire pressure or incorrect © Check tire pressure and preseure tront to rea Inflate deflate as ne © Incorrect tire size or incorrect © Correct as required. ‘ype. © Radial tras (misaligned beks). Replace as required. Frontand/orresrwhee!bearing | @ Refer to Sections 04-01 and/or loose or worn. 0a02, © Loose or worn rear suspension. © Tighten or replace as necessary. Refer to Section 04-00. © Loose flex coupling bolt © Tighten. Improper brake operation or © Inspect and adjust, Correct as adustment. afer to Section 08-00. Vehicle unevenly loaded. 2 Comect as requires. SPECIFICATIONS STATIC STEERING WHEEL TURNING EFFORT venice Power “Taurus/Sabe,Teurus SHO 2a7Ka (6.18) wan VAP “ecrue Sabie wihaut VAP ‘Sree ou) POWER STEERING RELIEF PRESSURE in Rote! Preseure Venicle We BL, AGL nd Taurus Potce 3.8L 650) ‘3.04/32 SHO 0650) SPECIAL SERVICE TOOLS ROTUNDA EQUIPMENT Wedel Description ora00207, Power Steering Systm Analy 2100014 acu Testor (014-00208 "Faure 01/9 20 SAO Fitna 1900 Teurue/Seble July, 198211-02-1 Steering System, Power 11-02-1 SECTION 11-02 Steering System, Power suavect pace sunscer ace nqueruenrs oigagsensty ao asensyconts) sioaro “shes iioner nota an 02.87 10288 110287 11-02-10 202-10 Varlable Assist Power Stosring (APS). DIAGNOSIS AND TESTING 1 Component Diagnosis.. ‘ie Roa Articulation Torque Check . DISASSEMBLY AND ASSEMBLY ‘Gear Housing, Rack Yoke Plug, Rack 1-02-26 1-02-55 120248 102-48 4-02-80 20248 10261 ‘and Return Line Fitting Bteoring Ges Steering Pump.. aontt 11-02-37 14-02-36 "1102-36 19-02-28 Rotary Valve, VAPS REMOVAL AND INSTALLATION ci Romoisiiscsrval ‘Steering Gear . SPECIAL SERVICE TOOLS. SPECIFICATIONS VEHICLE APPLICATION. VEHICLE APPLICATION ‘Taurus/Sable. DESCRIPTION Steering Gear ‘The power steering gear isa 16:1 constant ratio ower rack-and-pinion design for al vehicles except ‘Taurus LX and Sable. ‘The gear housing and valve housing are combined into ‘ one-piece aluminum die casting. The gear design incorporates quick connect fittings for the pressure ‘and return ines that allow the lines to swivel; this is rharmal and does not indicate loose fittings. Irth fittings leak, chack to ensure they are tightened to 414-20 Nim (10-15 lbs). Do not overtighten. i the leak isnot corrected, replace the fitting seals. ‘The gear is a hydraulic: mechanical unit, which uses an integral piston and rack design to provide power-assisted vehicle steering control. Intemal valving directs pump flow and controls pressure, as required, to reduce steering effort during operation. ‘The unit contains a rotary hydraulic fd control valve integrated to the input shaft and a boost cylinder integrated with the rack. NOTE: The power steering gear used on the Taurus ‘SHO utilizes travel restrictors mounted inboard of the ball joint housings. The restrictors limit wheal travel to prevent the tires from hiting the wheel housing. 7995 Tae Sabie Jay, 1992Steering System, Power 11-02-2 02. DESCRIPTION (Continued) NOTE: GRIP TIE ROO ON HEX FOR SETTING TOE ONLY. DO NOT GRIP ON THREADS. Part Part item | Number _| Description item | _Number__| Description 1 [axiser Spindle Assy ‘28 | NO02966-S160 [Nut @Req'a) 2 | 3504 Gear Ascy 9 | 3F540 Shiela 3 [80426-5150 | Bolt(2Req’a) soc |Ne10957-835 | Bolt (2 Req'd) 4a |1Na02637-838 | Nut (2Rea'a) A Tighten to. 47-88 Nm(35-50 5 [3280 10d End Assy (2 Req'd) Lory a Cotter Pin (2 Req’s) 8 Tighten to 115-196 Nm 7A_|nao2072.$160_| Nut (2Reg'a) ies 100 O © Tightento.9.5-8.0Nm (49-71 ‘Continued iat 7986 Taurue/ Sable duly, 199211-02-3, Steering System, Power 11-02-3 DESCRIPTION (Continued) ‘Taurus/Sable 7995 Taurus Sable sy, 106211-02-4 Steering System, Power DESCRIPTION (Continued) Part Pat term | __Number item | Number _| Description + [abser 26 [Neoasa7S | Seal Sratust Soa tr |asre Bushing 2 [eno Snap Ring 26 | 3508 Pa 3 |aose6 Power Steering Gear int ze [evezos | SrapRing eee em 30 | SFS20 Seal + | aoses Power Steaing Ceerlput — Stat Beary a |-— Piston Paro 9575) 5 [oscars | Snape ae eee ¢ feces [Beet at [ace Steering GesrHousing Assy & [soci | Power Soorns Gear input eat |r La ‘Shaft and Control Assy 36 | sasene-s Seal © | sor ea am focrst TransierTube Connector ae [neces | Pug 10 | srste Spring 114 | 3F608 Yoke Plug Locknut 7 ee Check Valve UA | sree oo son | aria Tanstr ube Assy 13 | 3F515 ‘Sector Shaft Support Yoke. am | sar7 Gaara 14 | 2662 Steering Geer Worm Beering a Tighten to oo-sam (44-98 sso fausae.sico [ut ghtento 55.8 4-50 iso | see Slowing GatrHoving Cover 2 Tphientos-sonimd 47 | 80850 c Tighten to 41-54N-m (31-39 128 | Neoseor-s irs 1a | 22s . Tonten to $4.0 (40-50 20F | N803259-S Clamp Lb-Ft) 21 [acre Breathe Tube E Tontent 47-60Nm (9580 a |— Spindle (Pat of 9200 LF 23 | 9280 Tie Rod Assy F ie eee 2 | Rotman ot 280) ase | Balint Housing Perot ; Inpro resanin cess 200) 4 Tightento 197 Nem (10-20 Conwnd ISS 75s Fauna /Sable July, 1992DESCRIPTION (Continued) Variable Assist Power Steering (VAPS) ‘The variable assist power steering (VAPS) system consists of a microprocessor-based module, a power rack-and-pinion steering gear, an actuator valve assembly, hose assemblies, and a high efficiency Bower steering pump for TaurusLX and Sable 3.0L and 3. vewoue ee Sana The system uses a modified rotary valve in the gear with two independent hydraulic circuits called the primary and secondary circuits. During parking and low speed operation, the flow from the pump is routed. {othe primary circuit by an electrically controlled ‘actuator valve assembly. As vehicle speed increases, the actuator valve gradually opens, diverting an increasing amount of fluid to the secondary circuit. The actuator vaive is a pressure-balanced variable orifice valve, controled by a stepper motor-driven linear spool. The VAPS module receives inputs froma vehicle speed sensor, and signals the stepper ‘motor-driven spool to adjust the opening of the actuator valve. The VAPS module is programmed to perform a self diagnostic check every 16 miliseconds. fa ‘concer is detected, the module microprocessor deactivates its outputs. ‘The VAPS module is programmed to perform a service diagnostic procedure when activated by the service ‘technician, 1906 Teurue/Sablo duly, 10024 Steering Syst 11-02-6 DESCRIPTION (Continued) NOTE: GRIP TIE ROD ON ‘SERRATED SECTION ONLY FOR SETTING TOE: DO NOT (GRIP ON TIE ROD THREADS. cmos van Pan ee tem| _nunter | pescipion Tanase Yon r= Sess 2 [moar [tence 28 [remosesuo [metttona & |fetesrooe [istics (Seen |S 5 |Fatecioo | eowerrwtced { Seer aonaoe0 6A | N803972-S150 | Nut (2Req'd) . ee m nemrasin | nacere' hn tm S309 | oteter aa ai ma 7963 Tauraa/ Sable duly, 108211-02-7 Steering System, Power DESCRIPTION (Continued) VAPS Exploded View Part Pert ttom | _number | Description item | Number | pescription 7a [88 Bot 7 [= i Joint Housing Pan oT 2 | 3648 ‘Steering Gear Housing Assy 280) 2 [sees Seer 12 | onsoe fevator sy fe lee ele A ‘ohn 027 94th (20-28 5 [eam Boot 5 Toten to 47-66 (5650 ec |neoseses | Ciamp Tanto 47-68. > | 3ere2 SreathorTibe c ento22-3.4Nm(2099 & | 3280 Tie Rog Assy wr o |= Somat od (Paro 200) > Tohtento 75-888 (65:85 wt Rolie arto 280) ies ‘Continued Tose Steering Pump, Ci The Ford Model Cll power steering pump is a belt-driven, 10-slipper type pump with a {iberglass-flled nylon reservoir. The reservoir is attached to the rear side of the aluminum pump housing, and the pump body is encased within the housing and reservoir. The pump design incorporates. ‘a pump pressure fitting which allows the pump pressure line to swivel. This is normal and does not Indicate a loose iting, 1909 Taurus Sable July, 198241-02-8 ‘Steoring System, Power 11-02-8 a cE BLS DESCRIPTION (Continued) ‘A pressure-sensitive identification tag is attached to the reservoir body. This tag indicates the basic model rnumber and the suffix. CAUTION: Always use the model codes on the tag when requesting service parts in case of differences in internal components. Refer to Section 11-00 for an example of this teg. 1900 Taurus /Sable Jy, 198241-029 ‘Steering System, Power DESCRIPTION (Continued) 11-02-0911-02-10 Steering System, Power 11-02-10 DESCRIPTION (Continued) Pert Part item | __Number__| Description item | _Number__| Description 1 | 3F68s Retainer Assy 12 [80544 Valve Cover Assy 2 | apse2 ‘Shatt Seal 13 | 3as7e Reservoir 3 | sass PumpHousing Plate 14 | 3878738 Retaining Ring 4 [3875728100 | Seat 15 | sagas Upper Piate 5 |s0s06 Bellevile Spring 16 | 38608 Valve Body 6 |387589-s100 | Seat 7 | saase0-s Seat 7 |3878700-8100 | Se 18 | sa008 Dipatick 2 | 3075705 Dowel Pin (2 Req'd) 18 | 30853 Outlet Fitting 9 | 30890 LowerPiate 20 |agsa7s-sos | Seat 10 | soe07 Gam and Rotor Assy 21_| apse6 Spring ix_| 98599 Shaft cae ‘Continued Power Steering Hoses Atsugi Steering Pump ‘The power steering hoses use O-ring seals at the quick connect fitings. Note that there are two possible leak points. Power Steering Pump and Gear Connection ‘The Atsugi power steering pump is a belt driven, vane-type power steering pump. The pump uses a emote reservoir mounted on the RH fender apron, an. oil cooler and a special quick connect fiting at the ump outlet. 1690 Taurae/Sablo July, 196211-02-11 Storing System, Power OPERATION Rotary Valve flow. ‘The rotary design control valve uses relative rotational ‘motion of the input shaft and valve sleeve to direct fuid ouren ruse ou row ou row (eibns tia ruon, Be Taw Cae Setwcen Beton G Ot our — aeruAW une Se ; = = oe a fu =r ‘When the steering wheel s turned, resistance of the wheels and the weight ofthe vehicle cause a torsion bar to deflect. This deflection changes the position of, the valve spool and sleeve ports, directing fluid under pressure to the appropriate end of the power cylinder. The difference in pressure forces on the piston helps move the rack to assist turning effort. The piston is attached directly to the rack, and the housing functions as the power cylinder. The olin the opposite ‘end of the power cylinder is forced to the control valve ‘and back to the pump reservotr. When the driver stops applying steering effort, the valve is forced back to a cantered position by the ‘torsion bar. When this occurs, pressure is equalized ‘on both sides of the piston, and the front wheels tend foretumn to a straight-ahead position Rotary Valve, VAPS ‘The rotary design control valve directs fui flow using relative rotational motion ofthe input shaft and valve sleeve. 1608 Town Sable Jay, 18211-02-12 Steering System, Power 41-02-12 ce nach A EN SEI EE ET OPERATION (Continued) When the steering wheel s turned, resistance of the heals and the weight of the vehicle cause a torsion bar to deflect. This deflection changes the position of the valve spool and sleeve ports, directing pressurized fluid to the appropriate end of the power cylinder. The difference in pressure forces on the piston helps move the rack to assist turning effort. The piston is attached directly to the rack, and the housing functions as the power cylinder. The ollin the opposite end of the: ower cylinder is forced to the control valve and back to the pump reservoir When the driver stops applying steering effort, the valve is forced back to a centered position by the {orsion bar. When this occurs, pressure is equalized ‘on both sides of the piston, and the front wheels tend ‘torreturn toa straight-ahead position. DIAGNOSIS AND TESTING ‘The diagnosis charts provide procedures to resolve typical customer concerns encountered with the power steering system Follow the sequence indicated to save time during ‘condition identification and corrective action. Power Stooring Diagnosis Before any internal service is performed on the rack ‘and pinion power steering, diagnosis ofthe condition must be performed, Ensure that the tire size is correct, with matened ties (front and rear), al inflated to ‘specifications. The following conditions, possible ‘sources and corractive action will assist in performing the proper service. Is Feit in The Steering Wheel By Gear assembly mounting loo ‘The Driver When The Vehicle Is |* specitication, Driven OverRough Pavement, | @ Piston disengaged orioose.on © Replace rack assembly rack. | ‘© Column intermediate shatt © Tighten bolts to specification. connecting bolts loose. © Loose suspension struts or bal (© Acjustorreplace as necessary, joints POWER STEERING DIAGNOSIS ‘CONDITION POSSIBLE SOURCE ACTION ‘© Wander: Condition Whare Vehicle | @ Loose tie rod ends. Replace tie rod end assembles, Wanders Sige-To.Side On the |@ hiner ballhousingioose orwom, | @. Replace te rod assemblies, Roadway When Being Driven ‘© Gear assembly mounting loos ‘© Tighten mounting bottto Straight Anead Whilo The Steering specification. WheellsHHeid ind Flim Position. | @ Loose suspension struts or ball © Aalust or replace as required. Evaluation Should Be Conductea | joints. © Column termediate shatt © Tighten bolt to specification. connecting bolts ioose. | ‘© Colmnintermediate shattioints je Replace intermediate shaft Tose or worn Improper whee! alignment. ‘© Sot alignment to specication @ Foedback—Fi Column Uints loose, knocking Notses Inthe St Loose tle rodends. Gear, Condition Where Roughness | © Loose/worn ie rod ball, ph Tighten mounting 7990 Tours Sable July, 196211-0; Stecring System, Power 11-02-13 DIAGNOSIS AND TESTING (Continued) POWER STEERING DIAGNOSIS (Continued) ‘CONDITION POSSIBLE SOURCE ‘ACTION © Poor Returnability— Sticky Feok |e © Align cotuma, Condition Where The Steering Falls To Return To Genter Wheel and/or ange, FoliowingA Turn Without Menual |e Cheok rotational torque of © tingling, replace intermediate Effort From The Driver. In Addition, | intermediate shatt joints. shat ‘When The Driver Returns The ‘Steering To Canter thay Have A Sticky Or Catchy Feel. Tight od balljonts. ‘ight imer te fod end bal stud Binding in valve assembly. © Replace tie rod as required. © Replace tie rod end as Bent or damaged rack, Bent or damaged subtrame. Colum bearing binding, © Tight suspension struts orlower ‘control arm ball jolts Improper wns! alignment. © Sotto specitication, © Conteminationin system. © Flush power steering system, {Improper yoke clearance (ight). Sotto specification ‘© Heavy Steering Efiorts — Poor or [© Leakage/loss of tld ‘© Relero external leakage oes of Asalst: Condition Where A dlagnosis tor service. Heavy Etfort And Poor Assist © Low pump fl. © Fillae neces: Condition's Recognized ByThe | @ Valve seal cut ortwisted, © Replace seal DriverWnile Turning Comers And |® Dameged/wom Tellon® piston © Replace seal Especially While Parking. ARoad ea Test Wil Verity This Condition. |@ Loose/missing rubber backup © Replace/install O-ring, piston Oring ° lace rack assembly, . Clear’ service as require. © Bent/ damaged rack assombly © Replace rack assembly ‘© Pumpextornal © Service per Pump Diagnosis. © improper © Reagjust belt tonelon, © Hose or coolerexiemalieakage. | © Replace as necessary. ‘© Improper engine Idle speed. ° © Pulley loose or warped ° 2 pulley, © Pump/tiow pressure not to Refer to Pump Service Diagnosis. specification © Hose cooler line restrictions, © Clear orreplace as require. Tee FORD INTEGRAL POWER RACK-AND-PINION STEERING GEAR ‘CONDITION POSSIBLE SOURCE ‘ACTION © Hiesing Souna © Hiss maybe expeotedwhen he ‘© ‘Hissis anormal charactoritie of ing wheelle al the end of rotary steering gears anginno wey ‘or when tuming at standstl affecte ster I ‘power steering systems. One of the most common is ahissing | sound most evident at standsti Barkio. Ther eno relationship tween this noise anathe. periommance ofthe stenng goer. ‘placement ack ale oxhbit 2 slight noise andisnot alwayea {cure forthe condition. Investigate fora grounded column or loose boot atthe dash panel Any CAUTION: Do not hold steering wheel at fulllock more than five Seconds, as damage to power passenger compartiment through steering pump may resul. the steering column. Verity clearance between fexibte coupling components, Eneure steering column shaft and gear a aligned so exible coupling rotates ina'flat plane ands not distorted ‘5 shat rotates, eso226 7903 Taurue/ Sable Jy, 199241-02-44 DIAGNOSIS AND TESTING (Continued) Steering System, Power External Leakage When looking for leaks, use this procedure to pinpoint the exact cause and location to avoid mis-diagnosis: 1. Check for overflled power steering pump reservoir 2. Wipe suspected area dry. 8. Check for power steering pump overflow and aeration, 4. Check for exact source of oi. Example: Oil may. 'be running down fram anothor area (engine, etc.) ‘and drip may not be leak point. CAUTION: Do not hold the steering wheel against a stop for more than three to five ‘seconds at a time, as damage to power steering pump may result. Cy tearing ‘wheel from stop to stop 10 times and check for loaks. The bellows may have to be moved back from the housing to see the leak. ‘Some leaks are high presoure leaks and may require holding steering wheel against stops to seep out. 6. Power steering gear assembly leaks fal ‘several categories as listed in the Leakage Diagnosis chart. The category determines which ‘seals or parts to replace. Refer to the: corresponding iltustrations for the leak category. LEAKAGE DIAGNOSIS Leak Category Part Requlvedto Service ~ Loose —hahiento speciiesion—Do wot oversight. 2 Leskat (rahi oriei)wanater in, '> Loose —Tighien to epeciiclion 0 not oversighton, > Replace pati seats 1S Repiacs ine aseembly as ceauirod ‘S Leakatinput chal sea ‘@ Replace input shaft seal ki, Rack and We rod assembly removals not require. J Leak at eiherorbotn bellows. ‘ Replace algearhousing end rack bushing transfor nas ale, Doak deur T Leak et end ofnpul shat To Repace pat save covery slong wt oa oe ene @ foveing porosity, cached or aipped tends [= Repiace the housing assert. Replace components such as input shaft/ valve ‘assembly or rack assembly only if the sealing ‘surfaces cannot be cleaned satistactorily with ‘erocus cloth. NOTE: Whenever a gear assembly is disassombled suse wut pusno House for seal replacement, the gear seal contact surfaces nose on Sian coe BAL should be checked for roughness and cleaned. Tse ASS Nev hose Asse anys ResLace (Sole Set or ‘fa aeal ArTER UN Semencacen, renova cosnana ToGsTaurve/ Sable July, 1092 11-02-1411-02-15 Steering System, Power DIAGNOSIS AND TESTING (Continued) a oxen Ccecuep nuusens connesPoND @ Tosa pow! cargoonies re LEAKAGE OINGHO CHART © ow bueToronosry crac ok Strep TREADS @ cue Pump Noise, Ateugi Test Procedure NOTE: The power steering pump is serviced as an For test procedure refer to Section 11-00. assembly. f any service is required, the entire pump assembly must be replaced, Refer to pump noise diagnosis chart. 7908 Taurae/ Sable duly, 190211-02-16 Steering System, Power 11-02-16 1 peace So AA EO ESI DIAGNOSIS AND TESTING (Continued) Pump Noise, Cli Refer to the pump noise diagnosis chart. PUMP NOISE DIAGNOSIS leakage. “CONDITION POSSIBLE SOURCE ‘ACTION © Power Steering ~ Gheck belt for proper tension or | © Tighten or replace belt as required glazing 2 Pump Nowy Low fluid lavel and possible Rell © epediied lovel Purge air from system. Check for leaks. Service as required. Swieh-Type Novse “> Flos flow into the bypass valve of | © Normal noise the pump valve housing wit fut temparature below 54°C (190°F} ' Wrine Type Nose ‘camaged, ‘ Aerated fsid, or cam contour Purge sysiom of air condition is ‘nol resolved, replace rotor assembly ® Clicking Mechanical Type Noise ‘> Pump sippers too long, excessive | © Replace roior assembly ‘wear of purnping elements. Excessive sipper to slot clearance, ‘or out of square slipper springs. ‘ Chatter Type Noise " Chipped comers on rotor outside © Replace rotor assembly. ameter oF distorted slipper spring. @ Other Cause of Noise “Improper aasombly Of components | © Rebuild pump and replace such a8 slippers. ‘components 2s required. €@ lmpertections on rotor outside ameter or ror end surace, ‘© Damaged rotor splines. «© Hite crack on cam inner surface. | © Replace rotor assembly. «© lnterforance betwoen rotor and © Excessively wom or scored «© Replace rotor assernbly and furnping eloments and pressure pressure plates. plates. © Replace rotor assembly. ‘© Replace rotor assembly. ‘© Foplace rotor assembly. ‘CG408e-C. ‘The diagnosie charts provide procedures to resolve ‘typical concerns encountered with the power steering system. Follow the sequence indicated to save time during ‘condition identification and corrective action. Electrical Component Diagnosis Tools Required: ‘© Rotunda Digital Volt Ohmmeter 007-00001 @ Rotunda inductive Dwel-Tach-VoltOhm Tester (059-0010 ‘Tris portion of the power steering diagnosis refers only to the electrical components of the VAPS system: @ VAPS Control Module © Spoed Sensor © Actuator Valve © Wiring Harness and Connectors 900 Tauroa/ Sable duly, 105211-02-17 Steering System, Power DIAGNOSIS AND TESTING (Continued) ‘The procedure is @ systematic mathod of determining Which of the above components, if any, require servicing. Testing can be done using Rotunda Digital \Volt Ohmmeter 007-0000 1, Rotunda inductive welt Tach-Volt-Ohm Tester 059-000 10 or equivalent. rea] eed eg soe ! ee 1995 Tourer /Sable Jay, 108211-02-18 ‘Steering System, Power 11-02-18 DIAGNOSIS AND TESTING (Continued) {A diagnostic connector is located in the engine ‘compartment near the brake tid reservoir and brake booster. Dbacuosne connecron PINPOINT TEST A. VARIABLE ASSIST POWER STEERING ELECTRICAL COMPONENT DIAGNOSIS TESTSTEP I RESULT B[_ACTION TO TAKE Hi WOOmECECR "© Turnignition switch to OFF. | cotoaz. Fae St Samet 100 enone caper ous bake booster © Connect DVOM positive lead (R) to Circuit 606 and Peo Sebald 0 tovec oun | vince ros > connect overvotags | | above 14volts Condition then GO 10 A2. aston VOM where ican be obsoved eran [__£ Se aoe ening on OVOH, 7809 Taurve Sabie Sly, 195211-02-19 ‘Steering System, Pows DIAGNOSIS AND TESTING (Continued) 11-02-19 speedometer. Eviorte nbalencediett to Fight PINPOINT TEST A VARIABLE ASSIST POWER STEERINGELECTRICAL COMPONENT DIAGNOSIS (Continued) TEST STEP RESULT B]__ACTIONTOTARE AE [WOOULE CHECK © Turn igntion switch 10 OFF Etiort changes >| cotoas. Connect an anlogvotimeter son Stop A1 with 2 sweeps © Uelimpersere and oroune ical 200, ne >| corar. wiih owoepe Etortchangewih | GOt0A19. Asweens | No tfor enange >| coioars. wih oweepe Etiorchangewin | Goto Az. Soweepe No offortchango Pl cotoata. assaoa | tho weeps © Start engine Effort change with >! cotoazo. © Rotate steering whee for approximately 00 O'sweeps Seconds nating any changeain steering efor: The | Noort change P| cotoara. Stor requredte lum the steering whoa! shouivary | naesureoat | Botwoer light andheevyinboin directions | © Aeraporeninatety 20 saeondsvottnetet wil Showe sweop pattern tou times between battery ‘olage an roroltmocne proveout Ok. Sor Zero sweopsita systom component imatonctioning, Aor eve second pause, the Swoop patter il erepested @ Remove Cicut 200 grounabetore proceeding to | nemtioat 7S_[ FUSE CHECK [7 fapec ne ocean wo panoton alae Bolow — | You >| coroars. Inatorent pane iunent No >| REPLACE uss, Coto At, 7a [TESTORIVE VERIOLE Ensure VAPS syeiemis comecied Changeinstoering Diagnostics complete © Diivevehicie uptossmphandsetspeedcontol._| sitar Syetomis OX © Dosteeringettorte change andissttertbalanced | prctonyathigh Bl coreare foeee © We geiving vehicle, note i >| coronas. >| REPLACE eteering gear assembly. REPEAT As. a SPEEDOMETER CHEOK ‘© Note operation of speedometer and apeed contror (rom Stop AA). © Arespeedometer and speed control operating properly? The VAPS system requires @ speed sional from the vehicle speed sensor Ifthe speedometer or ape Control does not work, these systems should be serviced using the appropriate diagnostic and Sanvice procedures. Yes No vv Gotoas. SERVICE as required. GO| 1oA4. 1609 Tawa Sable July, 10211-02-20 Storing System, Pow: 11-02-20 rs RIESE NE ARNE ST DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A VARIABLE ASSIST POWER STEERING ELECTRICAL COMPONENT DIAGNOSIS (Continued) ‘Connect DVOM ac © Measure resistance. ‘Gireulte 180 and 563. ‘TEST STEP, RESULT ‘B]__ACTION TO TAKE 7 [SPEED SENSOR CIRCUIT CHEGR ‘@ Disconnect VAPS connector from module. Resistance is. >) REPLACE VAPS module. between 160-225 ohms Resistance ie lose ‘than 1600F Sreater than 225, hme Gotoad. | > SERVICE hamess, GOto aa, ‘© Disconnect actuator connector from VAPS harness connector ‘© Turmignition awitch to RUN. 1S Waittive seconds. Measure DC voltage between Cicult 495 and ‘round. Then measure voltage between Circuit 496 and ground. © Ono ofthese two circuit Volts and the other Should be greater than 10 "2volts Do voltage readings check OK? 49 sr HARNESS ‘CONNECTOR 95328-4 = 408 46 Ropeat the two stops above for Circuit 497 and 408. wantless ‘CONNECTOR ee od GS82r-A, TF” AGTURTOR ELECTRVGALYGHEGK "@ Turn ignition switch to OFF. Resistance P| Gotoas. Seer err conmactrtommodule, | between sand 3 eetna vont to Gucets sas ana.co0, soctene © Measure resistance. Resistance less P Gotoato. Thang orgreter Ranroshns oo HARNESS CONNECTOR #95 ——_—BSZE-A | 6 “Conect ovoM ecru 497 and 408 fieucuerasaasce 76 [HARNESS VOLTAGE AY ACTUATOR COWWECTOR t ‘Turn ignition switch to OFF. ‘Yes BP) Gotoas. WeagatAScomccerecomectstovsrs | yp Foote esmodue. | GOI Az 7809 Tauro Sabie Jy, 195241-02-21 Steering System, Power DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A VARIABLE ASSIST POWER STEERING ELECTRICAL COMPONENT DIAGNOSIS (Continued) TEST STEP. RESULT B[_ACTIONTO TAKE ‘A9 [ACTUATOR (MECHANICAL) CHECK Turn ignition switeh to OFF. Yes D> REPLACE steering gear Remove actuator as outlined. assembly, GO to Az. (© Reconnect actuator connector to VAPS hamese No fe rertacs eam eo | connector, © Attach DVOM to dis Ae booster) as shown. nstic connector (near brake © Turnignition ewiteh to ON. “The module will go through sisting intially ofthe 80 assiea ‘R10 | ACTUATOR (ELECTRICAL) CHECK “Tur ignition switch to OFF. Resistance >! cotoars. Disconnect actuator connector rom harness. between 43 and connector, Oohme Connect DVOM to Circuits 495 and 496, Measure resiatance. 1) REPLACE actuator. 60 to} 22. 496. 496) ssrA DVOM to Clreult 497 and 498, Measure resistance. 7906 Taurua Sable July, 100211-02-22 Steering System, Powor ie rE a SE BENT ESDP DIAGNOSIS AND TESTING (Continued) 41-02-22 PINPOINT TEST A. VARIABLE ASSIST POWER STEERING ELECTRICAL COMPONENT DIAGNOSIS (Continued) © Measure resistance. ‘than 15 hme? 8 589 gsa24.k NOTE; All doore and hood must be closed for proper ‘eelatance readings. TEST STEP. T RESULT B_ACTIONTO TAKE 7a [Sonora [76 Turnignition switch to OFF. Yes P} cotoas. 2 Re a oe a mm modte S eeeemes ra oem teerccomo. | M > genvice tamess. oto Serer eerie rem sae : [ee Beene Baa WAPSPASNESS And CONNECTORS HECK Teron swine _ >) covwars, FRE RES Soc: ram nodule Yes | SERVICE names. 5 Bienes Ov Canta ana SERVICE nan 7906 Taurus Sable ly, 106241-02-23 Steering System, Powor RR A ESE RE FENG AS AY DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A VARIABLE ASSIST POWER STEERING ELECTRICAL COMPONENT DIAGNOSIS (Continued) TEST STEP, RESULT B]_AGTIONTO TAKE "A13_| VAPS HARNESS AND CONNECTORS CHEK Disconnect VAPS connector from module. Yes DP) cotoars. © Connect BVOM as shown, No D> SERVICE harness. REPEAT ATS. © Are voltage readings near given valuss? Vor ow rout Eunetion eo) | ee 208 Power Battery Top) 200. Diegeostic < Top. a7, “Actuator ea Tee. 498 ‘Actuator | sence ness. cote | Acces meneenences waa tree neve eee Sa ea coe een BS eee eS eee toe ee ee a ee = =e TOR ETRERTOEER "@ Connect VOM to Cirouit 495 and 496. Resistance >| REPLACE VAPS module. icon nee Reed Su a | Resistance tess. >| SERVICE harness or than 43 or greater than TO ohms connectors. GO10 A2- 7695 Tourue/ Sable July, 199211-02-25 ‘Steering System, Power DIAGNOSIS AND TESTING (Continued) 11-02-25 PINPOINT TEST A VARIABLE ASSIST POWER STEERING ELECTRICAL COMPONENT DIAGNOSIS (Continued) TESTSTEP, RESULT ci ‘ACTION TO TAKE ae \VAPS HARNESS ANO CONNECTORS CHECK % Tursignition switch to OFF No Disconnect VAPS connector from modul ae © Gonnect positive lead of DVOMt0 Circuit 87 and negative lead fo ground Measure resistance Ieresistance greater than 16 ohms? 298200487 57 498 150 Sat he NOTE: Alldoors and hood must be closed for proper resistance readings >| >| Gotoat7. SERVICE harness. GO10 at AI? [VAPS HARNESS AND CONNECTORS CHECK "® Connect positive lead of DVOM to Circuit 208and | Yes negative lead to Cireult 57. {© Tum ignition switch to ON. © Measure vottage. {© Turnignition awitch to OFF, @ Does DVOM reed 12 volts? vy Gotoars. SERVICE harness, GOto a ae ‘CONTINUITY CHECK @ Check continuity of Circuit 608 from diagnostic Yes Connector to module connactor. © lecireutt606 OK? a REPLACE module. O10 no SERVICE Circuit 608. G0 teat. ae \VAPS HARNESS AND CONNECTORS CHECK (vip PIN ‘© Tumigallion ewitch to OFF Yes Doors and hood must be closed for proper reading Connect DVOM ae shown. Measure resietance ‘and VIP Pin 7. Typical i © Monsure voitage between Circuit 87 (ground) and ‘VIP Pin. Typical voltage is tess than 0.1 vot © Isresistance ang voltage near given values? vv Gotoas, | ‘SERVICE hamess, GOt0 a 1969 Teurua/Sable Jay, 1002Steering System, Power 11-02-26 al DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A VARIABLE ASSIST POWER STEERING ELECTRICAL COMPONENT DIAGNOSIS (Continued) ‘TEST STEP, RESULT P| _AGTIONTOTAKE m20 ‘VAPS HARNESS AND CONNECTOR CHECK (DIAGNOSTIC CONNECTOR) “urn ignition ewitch to OFF Doors and hood must be closed for proper readings. Disconnect VAPS hamees connector from module. Connect DVOMas shown. Measure resistance between Circuit 608 of VAPS. hharnese connector and Circuit 606 of diagnostic ‘connector. Typical voltage oveleaset Creu 208 Measure eastnce {ween Circult 200 of VAPS harness connector and Grout 2001 diagnostic connector piel Feslatance i 2.0 ohms or ‘© Measure voltage between Circult 200 of VAPS fatness connactor and Circult 200 of clagnostic ‘connector. Typical vollage is ess than 0. 1 volt ‘© Isresistance and voltage near given values? VAPS HARNESS CONNECTOR CONNECTOR 696 200 Yes P| cotoaz. | SEAVICEnarness. GOto a2 1 2. Tie Rod Articulation Torque Check Toole Require ‘© Hook Spring Scale T74P-3504-Y ‘© Tie Rod End Remover TOOL-3290-D This check may be done with the gear on or off the vehicle. Disconnect tie rod end from spindle using Te Rod End Remover TOOL-3290-D or equivalent. Hook Spring Scale T74P-8504-Y over tie rod end ‘and measure force required to move tie rod. tf force required to move tie rods is not between B.9N and AN (2 Ib and 10 Ib), replace tie rod. recx can aso 96 SUSE aeons uoraweo 7858 Tawra /Sablo Jay, 98227 ‘Steering System, Power 11-02-27 DIAGNOSIS AND TESTING (Continued) eee ee ruse nut fuse wousne When looking for leaks, use this procedure to pinpoint ost on ‘the exact cause and location to avoid misdiagnosis: 1. Check for overfiled power steering pump reservor. 2. Wipe suspected area cry. 3. Check for power steering pump overtiow and aeration, 4. Check for exact source ofc. iimay be running down from anothe: area (engine, 0.) ‘and dip may not be leak point. CAUTION: Do not hold the steering whet apainst.e stop for more than thes tof atatime, as damage to power Steoring pumps) result Cyto feo stoorng wheel from stop-to-stop 10 times and check for leaks. The bellows may have to be moved back from the housing to eee the leak. 5, Some leaks are high-pressure leaks and may require holding steoring wneol againet stops to seep out 6. Powar steering gear assembly leaks fl into several categories as listed in the Leakage Diagnosis chert. the feak cannot be serviced by {ghtoning a iting to tho spoctiod toque, rplace ear. tf : sealer “iba seer ER cour Sea eMtice Ss et ons Eeyare. an © ay = = LEAKAGE DIAGNOSIS Teak Getegony PartRequlvedte Service Hose tgs. {Loose —Tighton to epecification—Do not over tah. 2, Leak at (ight orlet) wanater tne. = ‘3. Leakatinput shat cea ‘a. eplace gvaraseombly. “Leak a ether or bath bellows ‘a. Replace gear assembly 6 Leak atendatinpit shat. * 8. Hovsing —poroall,crackod or sipped vende Te Toma pcp mars comsrena sor TO LEAK POWT CATEGORIES: 7 S te toom TREES ohetess car sas ume wos Seon se Be, A _ i z 8 firs = —' ‘ 0 1693 Taurus Sable July, 199241-02-28 Steering System, Power 11-02-28 OE ner cn cree i SE FRE A SST REMOVAL AND INSTALLATION Remote Reservoir Removal 1. Loogen inlet and outlet hose clamps. 2. Remove hoses and allow fuid to drain into a container. 3, Remove retaining screw and reservoir from attachments. lation 1. Position reservoir to attachments. Tighten retaining screw to 6-8 Nem (64-70 Ib-in). 2. Instat hoses. Totten lamps to 1421 1317 Ibi) 3. Fillreservoir to proper level. Refer to Section 11-00. Remove engine damper strut. Refer to Section 03-018. Remove power steering belt. Raise vehicle on hoist. Refer to Section 00-02. Remove right front wheel and tire assembly. Position jack under engine. Remove right rear engine mount. Refer to Section 03-018. Remove power steering pump pulley. 8. Position drain pan. Remove pressure and return lines from pump. Remove four pump retaining bolts (three in front, ‘one in rear) and remove pump. Instaitation 4. Position pump and install retaining botts. Tighten retaining bolts to 20-32. Nem (15-24 lb). 2. Install pressure and return ines to pump. Remove ‘drain pan. 3. Install power steering pump pulley. Install right rear engine mount and remove jack. Refer to Section 03-018. ‘5. _ Install right front whee! and tire assembly. Tighten ‘wheel lug nuts fo 115-142 Num (85-105 Ib-f). Lower vehicle. Install belt to pump pulley. Install engine damper strut. Connect negative battery cable. (0. Fill power steering fluid to proper level. Refer to Section 11-00. ~ 999 aeane HOSE CLAP STUDS TO BE POSMONED AS SHOWN sat Part Item | _Number__| Description 1a [werriors2 | Screw 2 |3R700 Power Steering Reservoir Assy 98 }290462-S100 | Clamp(3Req'd) 4 | 493 Hose 58 |97242-s100 | Clamp (2Req'a) @ |3e01 Host 7 | a490 Bracket Assy 8 |Neoa710-s | Rivet (2Rea'e) A Tighten 106-8 Nem (54-70 Len) B Tighten to 1.4-2Nam (13-17 Lon) Power Steering Pump Removal 1. Disconnect negative battery cable. ‘Tle Rod End Replacement Tools Required: © Tie Rod End Remover TOOL-3290-D Steering Gear installed Removal 1. Remove and discard cotter pin and nut from worn tie rod end ball stud. 2. Disconnect tie rod end from steering spindle, using Tie Rod End Remover TOOL-S280-D or equivalent. 3. Hold tie rod end with a wrench and loosen tie rod jamnut. 14, Note depth to which tie rod was located by using the jam nut as a marker. Grip tie rod with a pair of ‘suitable pliers, and remove rod end assembly {rom tie rod. Installation 1. Cleantie rod threads, 2. Thread new tie rod end into tie rod to same depth a8 removed tie rod end. 7900 Taurus Sable ly, 199211-02-29 ‘Steering System, Power 11-02-29 a EI REN SND EE EEO REMOVAL AND INSTALLATION (Continued) 8. Place tie rod end stud into steering epindle, Ensure front wheels are pointed straight ahead before connecting stud to spindle. 4. Install a. new nut on tie rod end stud. Tighten nut to 48 Nem (85 lb-ft), and continue tightening nut to align next casteliation of nut with cotter pin hole in stud. Install anew cotter pin. 5. Set tos to specification. Refer to Section 04-00. ‘Tighten jam nut to 47-68 Nem (86-60 lb-ft). Steering Gear Except Taurus ix Removal 1. Frominside vehicle, remove nuts retaining steering shaft weather boot to dash panel. 2. Remove two bolts retaining intermediate shaft to steering column shaft 8. Set weather boot aside. Remove pinch bolt at steering gear input shaft and remove intermediate shaft. Raise vehicle on a hoist. Refer to Section 00-02, Remove LH front wheal. Remove heat shield. ‘Cut buncting strap retaining hydraulic pressure and return lines to gear. Remove tie rod ends from spindles. NOTE: The pressure and retum lines are on the front of the valve housing. Do not mix them with the transfer lines on the side of the valve. 9. Place a drain pan under vehicle and remove hydraulic pressure and return lines from steering gear. NOTE: The bolts are pressed into the gear housing and should not be removed during gear removal 10. Remove gear retaining nuts, 14. Push weather boot end into vehicle and it gear ‘out of mounting holes, Rotate gear so input shaft \will pass between brake booster and floorpan. Carefully start working steering gear out through LH fender apron opening. NOTE: If steering gear seems to be stuck, check RH rod to ensure stud is not caught on any obstacle. 12, Rotate input shaft so that it clears LH fender ‘apron opening and complete removal of steering soos ‘gear. Installation 1. Install new plastic seals on hydraulic tne fittings ‘ae outlined. 2. Insert steering gear through LH fender apron Rotate input shaft forward to completely clear {fender apron opening. To allow gear to pass between brake booster and floorpan, rotate input shaft rearward. 3. Align steering gear bolts to bott holes and install fetarng rte. Tighten to 116-136 Nem (86-100 lof). 4. Lower vehicle. NOTE: Swivel movement of fines is normal when fittings are properly tightened. 5. From engine compartment, install hydraulic pressure and return ines. Tighten pressure fine to 20-35 Nem (15-26 lb-t), and return line to 20-35 Nem (15-25 lb-ft). 6, Raise vehicle, 7. Secure pressure and return lines to transfer tube with bundling strap as shown, yore sectION A 8. Install heat shield. 98. Install tie rod ends to spindles, Tighten castellated ‘huts to minimum of 48 Nom (35 lb-ft). If necessary, tighten slightly more to align slot in nut for the cotter pin, 10. installa new cotter pin. 11, Install LH front whee! and lower vehicle, 12. Frominside vehicle, pull weather boot end out of vehicle and install over valve housing. 18. Frominside vehicle, install intermediate shaft to steering gear input shaft. 14, Install inner weather boot to tloorpan. 16. Install intermediate shaft to steering column shaft. 16. Fill power steering system with premium power ‘steering fluid E6AZ-19682-AA (ESW-M2033F) or equivalent. 17. Check system for leaks and proper operation. 18. Adiust toe setting. Refer to Section 04-00. ‘Taurus LX and Sable Removal 1. Frominside vehicie, remove nuts retaining steering shaft weather boot fo dash panel. 2, Remove two bolts retaining intermediate shaft to steering column shaft. 3. Set weather boot aside. Remove pinch bolt at steering Gear input shaft and remove intermediate shaft. 7985 Taurus’ Sabie Jy, 190211-02-30 Stoaring System, Power 41-03 REMOVAL AND INSTALLATION (Continued) 4, Raise vehicle on a twin post hoist and remove front whee! and tire assemblies. Refer to Section 5. Support vehicle with jackstands under rear edge (of subframe. 6. Remove tie rod cotter pins and nuts, and remove tie rod ends from spindle. 7. Remove tie rod ends from shaft. Mark position of jam nut to maintain alignment. 18. Remove nuts from gear-to-subtrame retaining bolts, Grebe sama sans sree 9. Remove rear subframe-to-body retaining botts. 10, Remove exhaust pipe-to-catalytic convertor attachment. 11. Lower twin post hoist carefully until subframe separates from body; approximately four inches. 412, Remove heat shield band and fold shield down. 1099 Tawa Sebo July, 186211-02-31 Steering System, Power 41-02-31 REMOVAL AND INSTALLATION (Continued) 18. Disconnect VAPS electrical connectors. ee SS11-02-32 Steering System, Power 11-02-32 REMOVAL AND INSTALLATION (Continued) Installation 4. _ Install new TFE O-ings online fitings as outined inPressure and Raturn Line Seal Replacement. 2. Place gear retaining bots in gear housing. Install goar through LH whee! well Install power steering line fittings to gear assembly. Ingtall VAPS electrical connectors. 6. Position gear into subframe. 7. Installtie rod ends onto shat. ‘8. Install band onheat shield. 8 ‘Attach tie rod ends to spindle. Insta nuts and new cotter pins. 7690 Yaurae Sable ly, 198211-02-38 Stecring System, Powor 11-02-33 Se RRR EEE RO RO ER A ECA SSE REMOVAL AND INSTALLATION (Continued) 10. Attach sway ber inks, 111. Raise hoist until subframe contacts body. 12, install subframe retaining bolts. Ks11-02-34 REMOVAL AND INSTALLATION (Continued) Steering System, Power 11-02-84 16. Install tre and wheel assemblies. Tighten wheel Tig nuts to 1 18-142 Nom (85-105 lb. 16, Remove jackstands and lower vehicle. 17, From inside vehicle, push weather boot end out of vehicle end instail over valve housing. 18. Inetall intermediate shaft to steering gear input shaft, Tighten bolt to 41-51 Nem (80-28 lb-ft) 18. Installinner weather boot to floorpan, 20. Install intermediate shaft to steering column shat. Rafer to Section 11-04. 21. Fillwith premium power steering fluid EGAZ-19582-AA (ESW-M2C33-F) or equivalent. 22. Bleed power steering system. Refer to Section 14-00. 28. Check system for leaks and proper operation. 24. Adjust toe setting. Refer to Section 04-00. Pressure and Return Lines ‘Taurus/Sable Removal 1. Disconnect battery ground cable. 2. Remove remote air cleaner. 2. Disconnect electrical connector in back of radiator fan motor. Disconnect electrical connector from purge valve. 5. Remove radiator fan shroud. 6. Disconnect integrated module hamess from headlamp harness and place module on top of ‘engine to provide accessibility to power steering lines. 7. Remove wiring harness guide retaining screws, ‘and position guide aside. 8. Remove screw at pressure and return line bracket. 9. Remove antirattie clip. NOTE: Removal of pressure switch may allow for additional tool clearance. 40. Disconnect electrical connector on power steering pressure switch at steering gear. 11. Remove plastic strap attaching tubes to steering gear. 12, Remove pressure line fiting at power steering pump using @ 6 /&:nch open-end wrench. 18, Loosen clamp and remove return line at pump. 414, Remove relum ine fitting at steering gear using an ‘8mm open-end wrench, 416. Remove pressure line fiting at steering goer, Using an 117 164nch open-end wrench. Installation NOTE: Pressure and roturn fitings have the same thread size. Ensure tho pressure nut (gold color) on line is inetalied in the prossure port, and that the check valves propery oriented. The return iting is siver colored and longer than the pressure line fitting. 1. Position power steering lines in vehicle and ‘connect lines at power steering pump and steering gear. Tighton fiting(s) to 34-46 Nem (26-33 bt). Tighten hose clamps to 1.42 Nem (18-17 bin). 2. Install screw at pressure and return line bracket. 3. Install antiraitle clip, 4, Install plastic strap attaching lines to transfer tube ‘on steering gear. 5. Connect power steering pressure electrical ‘connector to switch. 6. Install wiring harness guide. 7. Position integrated module to top of fan shroud ‘and connect module harness to headiemp harness. 8. Install fan shroud. 9. Connect electrical connector to purge valve. 10. Connect electricat connector to radiator fan motor. 11, Install remote air cleaner. 42, Connect battery ground cab 19. Fill system. Refer to Section 11-00. 7900 Taurwe/ Sable July, 196211-02-35 Stecring System, Power 11-02-35 REMOVAL AND INSTALLATION (Continued) 3.0LEngine Part Part Item | __Number__| Description ttem | _Number__ | Description 1 | 12267 ‘Engine Coll Bracket 7 [Sarto PressureHose Assy 2 |acst0 Bracket Asay ap |Nezies0.s2 | Nut 3 | ses11-s2 tip 9 | sNezs TFitting As 4 | 3a713 Power Steering Line Assy 10 |9se7s-sio1 | Retai 5 | aFse4 Power Steering Line Assy A Tighten to 4.56.7 Nem (40-50 ea_|Nerose-s2 | Boit : eros ighten to 8.1-1 ‘Contruesd ies Supply Line—Reservoir to Pump Taurus SHO Removal 1. Disconnect battery ground cable, 2, Remove engine damper shock. Refer to Section 03-018. 3. Remove power steering bett. 4. Loosen supply line hose clamp at reservoir and remove hose. 6. Drain fuid nto a suitable container. 6. Remove strap retaining supply line to return fine. 7. Raise vehicle on hoist. Refer to Section 00-02. 8 Remove RH front wheel and tire. 98. Position adlustable jack under engine. 10. Remove RH rear engine mount. Refer to Section 08-016, 11. Remove power steering pump pulley. 12. Position drain pan under pump. 18. Disconnect supply ne at pump. 114, Remove supply line from vehicle. Instaltation 1. Position supply line in vehicte. 2. Connect supply ine hose to purmp. Tighten hose clamp to 1.4-2Nan (13-17 bon). Install power steering pump pulley Install RH rear engine mount, Remove jack. Install wheel and tire. Tighten whee! lug nuts to 116-142 Nem (85-105 ft). Remove drain pan. Lower vehicle. 8. Install engine damper shock. pane 1903 Taurus/ Sable Jy, 1062‘Steering System, Powe 11-02-36 cee cern Rn SEES REMOVAL AND INSTALLATION (Continued) 10. Install strap to secure supply line to return fine. 11. Connect battery ground cable. 42, Fill system. Refer to Section 11-00. Pressure Line Taurus SHO Removal 1. Disconnect battery ground cable. 2. Remove engine damper shock, Refer to Section 03-018. Remove power steering belt. Rage vehicle. Refer to Section 00-02. Remove RH front wheel and tire. Position jack under engine. Remove RH rear engine mount. Refer to Section 03-018. Remove power steering pump pulley. 9. Position drain pan under pump. 410. Remove pressure line fiting at power steering pump, 11, Cuttie straps and remove heat shield around steering gear assembly. 12, Remove shift linkage mount bracket from iransaxle to gain access to high pressure line at ‘gear housing. 2 48. Disconnect electrical connector on power ‘steering pressure switch at steering geer. 14, Remove presaurs line fiting at steering gear. 48. Remove high pressure line rom vehicle. Installation 1. Position high pressure tine in vehicle and connect ling at power steering pump and steering geet. 2. Connect electrical harness to power steering pressure switch, Install shift linkage mount bracket to transaxle. Position heat shield around steering gear assembly and install tie straps. Remove drain pan. instal power steering pump pulley. Install RH rear engine mount. Remove jack. Intell wheel and tre, Tighten whee! lug nuts to 115-142 Nun (85-105 Ib). 10, Lower vehicle. 41, Install power steering bett. 42, Install engine damper shock. 18, Connect battery ground cable. 414, Fill system, Refer to Section 11-00. a were Cooler Lines, ‘Steering Gear to Cooler Taurus SHO Removal 1, Disconnect battery ground cable. 2. Raise vohicle. Refer to Section 00-02. 8. Loosen hose clamp at cooler. Disconnect line and ain fluid into a suitable container. 4, Remove shift mount bracket. 5. Cutie straps and remove heat shield from steering gear. 6. Disconnect hose at steering gear. 7. Lower vehicle. 8, Removehose from vehicle. Installation 1. Position hose in vehicle. 2, Raise vehicle. 3. Connect hose at steering geet. 4. Position heat shield and instal tie straps. 6. Install ehift mount bracket. 6 Connect line to cooler and tighten clamp to 1.42 Nem (13-17 losin, 7. Lower vehicle. 8. Connect battery ground cable. 9. Filleystem. Refer to Section 11-00. Cooler to Reservoir ‘Taurus SHO Removal 1. Disconnect battery ground cable. 2. Raise vehicle. Refer to Section 00-02. 750 Taurve Sable July, 188211-02-37 REMOVAL AND INSTALLATION (Continued) ‘Steering System, Power 3. Loosen hose olamp at cooler. Disconnect hose ‘and drain fluid into a suitable container. 4, Flemove shift mount bracket. 5. Cuttie straps and remove heat shield from steering gear. 6. Lower vehicle. 7. Loosen hose clamp at reservoir and disconnect return ine. 8. Remove hose from vehicle. Installation 1. Position reservoir-to-cooler hose in vehicle. 2. Connect hose to reservoir and tighten clamp to 44-2 Norn (13-17 bin). 8. Raise vehicle. 4. Position heat shield at steering geer and instal tie straps. 5. Install shift mount bracket. 6. Connect hose to cooler and tighten clamp to 14-2 Nem (18-17 Ibi). 7. Lower vehicle. 8. Connect battery ground cable. 9. Fillsystem. Refer to Section 11-00, Cooler ‘Taurus SHO Removal 1. Disconnect battery cable. 2. Loosen hose clamps at cooler and remove return lines from cooler. 8. Remove two actews retaining cooler assembly to ‘vehicle. Remove cooler. Installation 1. Position cooler and install two screws. Tighten to 48-28 Nem (14-20 b-f). 2. Connect return tine hoses to cooler. Position hose clamps and tighten to 1.4-2 Nem (13-17 Ibsn). 3. Connect battery ground cable. 4. Filleystem. Refer to Section 11-00. 7905 Teurue/Sablo July, 1992 11-02-3711-02-38 Steering System, Power 41-02-38 Se SEAR AS AEE REMOVAL AND INSTALLATION (Continued) THOSE CLAMP STUD TOBE WITHIN AREA SHOWN SODEGREES TE OL ; SSUES FLUID MUST SHOW ON DIPSTICK as: View OF PoweR STEERING PUNE DIPSTICK SHOWING FILL INSTRUCTIONS. HOSE CLAMP 45 48 GLAwP Mus BE 250 —]}-——— BEHIND TUBE BEAD} 250 ANDTO THIS DIMENSION ‘TYPICAL HOSE CLAMP CONNECTION. ROTATIONAL POSITION OF CLAMP UNLESS GTHERWISE SPECIFIED. QUICK CONNEGT INSTALLATION AT PUMP viewo viEWo . 7006 Tawra /Sable July 198211-02-39 REMOVAL AND INSTALLATION (Continued) Steering Sytem, Power 11-02-39 Part Part tom | number _ | Deser item | Number _ | Description + [aRr00 Power Steering Roser 148 [Ne10960-82 | Screw Rea hesy sf Speed Contre Soro 2 | sesto Clamp 12¢ | 0ce2:s100 | Gann onou'd 8 | sere: Hose Assy 70 Jossse2s | Clamp (anes) @ | sora Cooter assy 0 |raoerios — |rwetteneee) 8 | sere: Hose Assy to [esseses [Sect @ {sari Hose Assy 20 |naoarses | Se 7 | snore Power Steering Pump 21 | erase Housing 8 | seo Bracket 2 |— Hose Tube Assy 5 Engine Mounted Stud 23 |Neoarse-s | Seap ing ton |neeiecese [Nut a Tightent0289917 Nm 11a |neotaies | Nut Crssb FO 42 | 3NB03 ‘Actuator Assy, B Tighten to 4.0:5.6 Nem (38-50 13_| 95873 ‘strap = ae © Tohtento1.6-2.2Nhm (14:20 ishs Pressure and Return Line Fitting at Steering Gear and Power Steering Pump Tools Required: © Tetlon Seal installer DSOP-9617-A3 SeelReplacement Ifa leak occurs between the tubing and tube nut, ‘replace the hose assembly. If leak occurs between the tube nut and the aluminum gear housing or pump outlet fitting, replace the plastic washer. ‘The following procedure should be used: 1. Check fittings to determine which fitting is leaking ‘and whether leak is between tube and tube nut or ‘between tube nut and gear housing or pump outlet fiting. CAUTION: DO NOT over-tighten. If tube nuts are overtorqued stripping of housing threads may occur and bores may concave. 2, Iifleakiis between tube nut and gear housing or ‘pump outlet fitting, check to ensure nut is tightened to 27-34 Num (20-25 Ib). 3. _Ifleak continues or iffeak is between tube and tube nut, remove line. 4. Unscrew tube nut, and inspect plastic soa! washer. Always replace plastic seal washer (pressure line plastic washer at goar, 388897-S, and return ine plastic washer at gear or pump ‘outlet, 388898-S) when ine is removed. To {aciltate assembly of naw plastic seal washer, a tapered shaft may be required to stretch washer, 280 t may be sipped over tube nut threads. STRETCH PLASTIC SEAL OVER A TEFLON SEALINSTALLER (O00P-3517-43) OR & ‘TAPERED TOOL, SUGH AS A CENTER. PUNCH, UNTIL FFIS LARGE ENOUGH TO ‘SUP OVER THE FITTING THREADS. THE ‘SEAL WILL SLOWLY RETURN TO ITS ‘ORIGINAL DIAMETER. oo023.0 6. The rubber O-ring cannot be serviced with this design. Ifleak is due to the O-ring, replace the hose assembly. 906 Tavius/ Sable aly, 108241-02-40 REMOVAL AND INSTALLATION (Continued) Steering System, Power 11-02-40 6. Connact tube nuts and tighten to 27-34 Nem (20-26 lo-t) Install plastic strap to attach pressure and return ines to LH turn transfer tine. The quick connect fittings may disengage if not fully assembled, If the snap ring is missing, or ifthe tube rut, oF the hose end is not machined property. lt the fiting disengages, replace the hose assembly. ‘The fitting is fuly engaged only when the hose will not pullout. To test for positive engagement, the system should be properly filed, the engine started, and the steering whael cycled from lock-totock. Service hose assemblies have tube nuts, snap rings and O-rings already attached. Pressure Switch Tools Required: «© Rotunda Digital Volt Ohmmeter 007-0001 ‘The pressure switch uses an O-ring seal fa leak occurs, check that the switch is property tightened to 7-14 Nim (6-10 lf. I the leak continues, replace the (O-rings, then the pressure tube, and finally the pressure switch, Pressure Suitch Functional Check Check operation of the switch f either or both of the following concoms are noted: «© Engine stalls during parking manewers. © Engine ides at high epeed, “The folowing testis based on the fect thatthe switch is normally closed. As power steering Ioad increases, the ewitch opens and increases the idle speed. 1. Disconnect the electrical connector atthe pressure switch 2. Connect a continuity tester, Rotunda Digital Vot ‘Ohmmeter 007-0001 or equivalent, across the pressure switch terminals. 3. Start engine and\etidl. 4. Switch should be normally closed (zero ohms) with steering wheel straight ahead. 6. Turnsteering toward ether stop while watching continuity tester. Switch should open near the ‘tops (no continuity or infite reading on ohmmeter). 6. ewitch fais lther test, replace the switch. ‘switch is OK, check the engine idle speed control system. Quick Connect Power Steering Fitting, Cll Toots Required: © Teton Seal installer DSOP-3517-A3 ‘Seal Replacement la leak occurs between the tubing and tube nut, replace the hose assembly. Ifa leak occurs between the ube mut and the pump out, repace the pasic washer. “The following procedure should be used: 1. Check fitting to determine whether leakis between tube and tube nut or between tube nut ‘and pump outlet CAUTION: DO NOT over-tighten. if tube nuts, are overtorqued, stripping of housing ‘threads may occur and bores may concave. 2. Ifleak is between tube nut and pump outlet, check {to enaure nut is tightened to 27-34 Nem (20-25 Ib. 3. Hfleak continues or ifleak is between tube and tube nut, remove tine. 4, Unscrew tube nut, and inspect plastic seal washer. Always replace plastic seal washer (388898-S) when line is removed. To faciitate ‘assembly of new plastic seal washer, a tapered ‘shaft may be required to stretch washer, soit may be slipped over tube nut threads. ‘STRETCH PLASTIC SEAL OVER A TEFLON ‘SEAL INSTALLER (D90P-9517-A3) OF & ‘TAPERED TOOL, SUCH ASA CENTER, UNTIL TIS LARGE ENOUGH TO SUP OVER THE FITTING THREADS. THE SEAL WILL SLOWLY RETURN TOTS ‘ORIGINAL DIAMETER. e230 805 Tawra, 708211-02-41 REMOVAL AND INSTALLATION (Continued) Steoring System, Power 5. _Therubber O-ring cannot be serviced with this design. ifleak is due to the O-ring, replace the hose assembly. 8. Comect tube nut and tighten to 27-94 Nem (2026 bf. ‘The quick connect fiting may disengage if not fully ‘assembled, ifthe snap ring is missing, orf the tube nut ‘or the hose end is not machined properly. Ii the fiting disengages, replace the hose assembly. ‘The fitting is fully engaged only when the hose will not pull out. To test for positive engagement, the system should be property filled, the engine started, and the steering wheel cycled from lock-lorlock. Service hose ‘assemblies have tube nuts, snap rings and O-rings already attached. Steering Pump Removal 1. Remove radiator overtiow bottle to gain accest to three bolts retaining pulleys to pulley hub. 2. Mark both pulley-to-hub positions with grease pencil or paint dau for reassembly to maintain balance. 3. Remove the three bolts and two pulleys from. pulley hub, Instellation 1. Install two pulleys on hub, aligning marks put on ‘hub and pulleys during removal 2. Install the three bolts and tighten to 21-32 Nem (15-23 Ibe. 3. Install radiator overfiow bottle. ones 2. Loosenidler pulley and remove power steering belt. 3. Remove pulley from hub. 4, Remove return ine from pump. 5. Completely back off pressure line nut. Line wil ‘separate when pump is removed from bracket. 6. Remove three pump retaining bolts and remove pump. Instattation 1. Install pump on mounting bracket. Guide pressure line into pump outlet iting while installing pump. 2. Install pressure and return lines. Install pulley on hub. 4, Install steering pump drive belt and adjust tension. Refer to Section 03-05. 5. Connect battery ground cable. 6. Fill pump with uid and check operation. Refer to ‘Section 11-00, Steering Pump and Pulley Hub 8.0L Engine Removal 1. Disconnect battery ground cable, Pump Reservoir ‘Take the foliowing precautions when servicing the power steering pump reservoir: © Use clean work bench and tools, © Plug inlet and outlet openings of pump with plugs or masking tape. © Thoroughly clean exterior of pump with solvent. 1663 Toures Sable July, 198211-02-42 Steering S) 11-02-42 REMOVAL AND INSTALLATION (Continued) Removal 4. Place pump assembly ina bench vise with soft jaws and remove outlet iting, flow control valve, ‘and pring. Discard all seals. 2. Remove fiberolass reservoir by twisting side-to-side and lifting. 5001-8 CAUTION: Do not hammer on the reservoir. 7605 Taurea/ Sabla duly, 100231-02-43 Steering System, Power 11-02-43 REMOVAL AND INSTALLATION (Continued) 3. Discard O-ring seal on pump housing. Installation 1. Install new O-ring seal on pump housing. 2. Apply petroleum jlly to reservoir O-ring eel and inside edge of reservoir. Do not twist Oring seal, 3. Intl reservoir over pump and align outlet fitting hole in reservoir with hole in valve cover. CAUTION: If valve is cocked, It may becom stuck in the valve cover. Do not force valve forward. Forcing the valve may shear off metal and carry the metal chips into the valve bore, 4, Place new O-ing seals on outlet fiting. Install low control spring, low control valve and outlet fiting Into reservoir and valve cover. Tighten fitting to 33-47 Nem (2634 bf). ‘Arey perms sty Ny ois one: \ “rene deorces Steering Gear Actuator Removal 1. Remove air inlet duct for access to actuator. 2. Disconnect VAPS electrical connector from actuator, 3. Disconnect pressure ewitch, 4. Remove two actustorto-steeing gear retaining Ht. 5. _Liftactuator from gear assembly. VAPS ELECTRICAL ‘CONNECTOR. ast62-8 Installation NOTE: Ensure that the two eeale (between the actuator and gear assembly) are in place when eetting the actuator on the gear assembly 1. Align actuator on steering gear. 2. Install two actuator-to-steering gear retaining bolts. Tighten to 27-34 Nem (20-26 lb-ft). 8. Reconnect pressure switch and VAPS electrical ‘connector. 4, Install the air inlet duct. VAPS Module ‘The VAPS module is located below the instrument panel on the RH side of the steering column. Removal 1. Disconnect wiring hamess connector from VAPS module. 2. Remove three module fixture retaining screws from column mounting fixture and remove module. Installation 1. Align mounting holes of new module te mounting holes on columa mounting fixture, 2. Install three module fixture retaining sorews and tighten to 4-5 Nm (85-46 lb-in). 8, Reconnect wiring harness connector to VAPS ‘modu 1005 Teurse Sable Jay, 70022-44 11-02-46 DISASSEMBLY AND ASSEMBLY Tie Rods, Bellows ‘Tools Required: © Bench Mounted Holding Fixture T57L-600-B © Nut Wrench T74P-3504U © Locknut Pin Remover D81P-3504-N Disassembly 1. Mount gear assembly in Bench Mounted Holding Fixture T57L-600-8. NOTE: Drill out mounting holes in holding fixture with a 9/ 16-inch dri to alow the gear assembly ‘mounting bolts to fit. Remove tie rod ends, 8. Remove four clamps retaining bellows to gear housing and tie rods. Discard clamps if damaged or excessively corroded. CAUTION: Use care not to damage bellows. 4, Remove bellows along with breather tube. cszsna NOTE: For units equipped with ives in place of 7. Use side cutters to ry out arve pin. {he coed pins, porform Stops 6 and 7 8. Poston rack 0 that saveral rack teth re 5. Using Locknut Pn Remover D81P-2504N or exposed. old rack win an acstable wrench on ttulvalont, remove coled ick pins from Ine tle nd toeth ony. wel loosening bab jot ruts wth rodball ots. Nut Wrenon Pr aP- 3500-0. 6. With sharp chisel, gently tap around rivet head soit ite away from ball joint. Use caution so the ‘center pins not sheared off Assembly 1, Expose several rack teeth and hold rack with adjustable wrench. a0 Teurue/ Sabla sly, 1082