2003 FORD WINDSTAR Service Repair Manual.pdf

2002 2002 Ford Ford Winds tar 2002 STEERING Power Steering - Windstar

Inner tie-rod

100 74

(1) Once torque is reached, continue turning to align slot in nut with cotter pin hole in tie rod.

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Inner tie-rod

100 74

(1) Once torque is reached, continue turning to align slot in nut with cotter pin hole in tie rod.

DESCRIPTION AND OPERATION POWER STEERING Steering System Components - 3.8L Engine (CIII Power Steering Pump)


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Fig. 1: Identifying Steering System Components - 3.8L Engine (CIII Power Steering Pump) Courtesy of FORD MOTOR CO. Steering Gear Mounting



Fig. 2: View Of Steering Gear Mounting Component Courtesy of FORD MOTOR CO. Steering Gear (Typical)



Fig. 3: Identifying Steering Gear (Typical) Components Courtesy of FORD MOTOR CO. Power Steering Pump (CIII) - 3.8L Engine



Fig. 4: Identifying Power Steering Pump (CIII) - 3.8L Engine Courtesy of FORD MOTOR CO. Power Steering Pressure (PSP) Switch

A power steering pressure (PSP) switch (3N824) is located on the power steering pressure hose. It sends a signal to the powertrain control module (PCM) (12A650) to increase idle speed for idling stability when power steering pump pressure increases above the set pressure value. Power Steering Gear Identification


CAUTI CAUTION ON:: Always use the ID ID code when when ordering s ervice parts. parts.

The steering gear identification code is stamped into the housing.



The steering gear identification code is stamped into the housing.

Fig. 5: Identifying Steering Gear Identification Code Stamped Into Housing Courtesy of FORD MOTOR CO. Power Steering Pump Identification


The pump identification code is located on a tag attached to the power steering pump.



Fig. 6: Identifying Pump Identification Code Located On A Tag Attached To Power Steering Pump Courtesy of FORD MOTOR CO.

DIAGNOSIS AND A ND TESTING POWER STEERING

Refer to STEERING SYSTEM-GENERAL INFORMATION .

REMOVAL REMOVAL AND INSTAL INSTALLA LATIO TION N RESERVOIR - CIII PUMP Removal

1. Disconnect Disconnect the power power steering steering reservoir reservoir pump hose hose (3E525) and and power steering steering hose (3493). (3493). Remove Remove the screw and the power steering pump reservoir (3R700).



Fig. 7: Disconnecting Power Steering Reservoir Pump Hose (3E525) And Power Steering Hose (3493) Courtesy of FORD MOTOR CO. Installation

1. Follow Follow the the removal removal proced procedure ure in rever reverse se order. order. 2. Fill Fill and leak leak check check the the system system.. Refer Refer to to STEERING SYSTEM-GENERAL INFORMATION . PUMP - CIII Special Tool(s)



Fig. 8: Identifying Special Tool(s) Courtesy of FORD MOTOR CO. Removal

1. Remo Remove ve the the dri drive ve belt. belt. 2. Disconnect Disconnect the the power power steering steering reservoir reservoir pump hose hose (3E525). (3E525).



Fig. 9: Disconnecting Power Steering Reservoir Pump Hose (3E525) Courtesy of FORD MOTOR CO.

3. Disconnect Disconnect the the power steering steering hose hose (3A719). (3A719). Remove Remove and discard discard the the seal. seal.



Fig. 10: Disconnecting Power Steering Hose (3A719) Courtesy of FORD MOTOR CO.

4. Remove the the four bolts, bolts, two brackets brackets and power power steering steering pump pump (3A674). (3A674).



Fig. 11: Removing Bolts, Brackets And Power Steering Pump (3A674) Courtesy of FORD MOTOR CO.

5. Remove Remove the the power power steeri steering ng pump pump pulley. pulley. Refer Refer to to PULLEY - CIII PUMP . Installation

1. To instal install, l, rever reverse se the remo removal val proce procedur dure. e. 

Using the special tool, install a new seal on the power steering hose.



Fig. 12: Installing A Seal On Power Steering Hose Courtesy of FORD MOTOR CO.



Fig. 13: Installing Bolts, Brackets And Power Steering Pump (3A674) Courtesy of FORD MOTOR CO.



Fig. 14: Connecting Power Steering Hose (3A719) Courtesy of FORD MOTOR CO. PULLEY - CIII PUMP Special Tool(s)




1. Remove Remove the the power power steeri steering ng pump pump (3A674) (3A674).. Refer Refer to PUMP - CIII . 2. Using the special special tool, remove the power power steeri steering ng pump pulley. pulley.



Fig. 16: Removing Power Steering Pump Pulley Courtesy of FORD MOTOR CO. Installation

1. Using the the special special tool, tool, install install the the power steeri steering ng pump pulley. pulley. 

Inspect the power steering pump pulley for paint marks in the web area near n ear the hub. If there are two paint marks, discard and install a new power steering pump pulley. If there is no n o paint or one paint mark, use a paint pencil to mark the web area near the hub.



Fig. 17: Installing Power Steering Pump Pulley Courtesy of FORD MOTOR CO. 

Install the power steering pump. Refer to PUMP - CIII .

HOSE Special Tool(s)




1. Refer Refer to the the System System View View illu illustr strati ation on in DESCRIPTION AND OPERATION for the hose routing and retention points. Installation

CAUTI CAUTION ON:: While repairing repairing the power steering system, care shoul d be taken taken to prevent the entry entry o f contamin ants or premature failur failur e of the power power steering components can result. NOTE:

When hen con conne nect cting ing a fittin fitting g with with a Teflon( flon(R R) sea seal, a new new se seal must must be installed.

1. Using the the special special tool, tool, install install a Teflon( Teflon(R) R) seal seal over a fitting. fitting. 

Fill and leak check the system. Refer to STEERING SYSTEM-GENERAL INFORMATION .



Fig. 19: Installing A Teflon(R) Seal Over A Fitting Courtesy of FORD MOTOR CO. COOLER - FLUID Removal

NOTE:

The trans transmis missio sion n and and pow powe er ste steering ring fluid fluid cool coole er asse assembl mbly y (3 (3F749) is sho shown wn in in this p rocedure. The The removal removal and installation o f the other power steering steering f luid cooler (3D746) is similar.

1. Disconn Disconnect ect the the batte battery ry ground ground cable. cable. 2. Remove Remove the front front bump bumper er (1775 (17757). 7). 3. Label and disconnect disconnect the the power steering steering hose hose (3A713), (3A713), power steering steering hose (3493) (3493) and the transmis transmission sion fluid lines.



Fig. 20: Disconnecting Power Steering Hose And Transmission Fluid Lines Courtesy of FORD MOTOR CO.

4. Remove the the bolts and and the transmis transmission sion and power power steering steering fluid fluid cooler cooler assembly. assembly.



Fig. 21: Identifying Transmission And Power Steering Fluid Cooler Assembly Courtesy of FORD MOTOR CO. Installation

CAUTI CAUTION ON:: The power steering steering hos es and and transmiss ion flui d lines must be connected to transmission and power steering fluid cooler assembly as noted during removal to pr event event power steering syst em and and transmission failure.



Fig. 22: Installing Transmission And Power Steering Fluid Cooler Assembly Courtesy of FORD MOTOR CO.

1. To instal install, l, rever reverse se the remo removal val proce procedur dure. e. 2. Fill and and leak check check the power power steeri steering ng system system and transmi transmission ssion.. Refer to STEERING SYSTEMGENERAL INFORMATION . STEERING GEAR Special Tool(s)




1. Place the wheels wheels in the straightstraight-ahead ahead position position and the ignitio ignition n switch in the the OFF position. position. 2. Remove the front front wheel and tire tire assembl assemblies. ies. Refer to WHEELS & TIRES . 3. Remove Remove the the cotter cotter pins pins and caste castella llated ted nuts. nuts. 

Discard the cotter pins.



Fig. 24: Discarding Cotter Pins Courtesy of FORD MOTOR CO.

4. Using the special special tool, disconnect disconnect the tie-ro tie-rod d ends. ends.



Fig. 25: Disconnecting Tie-Rod Ends Courtesy of FORD MOTOR CO.

5. Disconnect Disconnect the the two heated oxygen sensor sensor electrical electrical connectors. connectors.



Fig. 26: Disconnecting Heated Oxygen Sensor Electrical Connectors Courtesy of FORD MOTOR CO.

6. Using Using the speci special al tool, tool, suppor supportt the flex flex pipe. pipe.



Fig. 27: Supporting Flex Pipe Courtesy of FORD MOTOR CO.

7. Remo Remove ve the the two two fla flang ngee bolts bolts..



Fig. 28: Removing Flange Bolts Courtesy of FORD MOTOR CO.

8. Support Support the front front subframe subframe with jack jack stands stands under under the front front jack jack pads. pads.



Fig. 29: Supporting Front Subframe With Jack Stands Under Front Jack Pads Courtesy of FORD MOTOR CO.


9. Remove the the nuts and disconnec disconnectt the stabiliz stabilizer er bar links links from from the struts. struts.


9. Remove the the nuts and disconnec disconnectt the stabiliz stabilizer er bar links links from from the struts. struts.

Fig. 30: Disconnecting Stabilizer Bar Links From Struts Courtesy of FORD MOTOR CO.

10. Remove Remove and discar discard d the the two two bolts bolts..



Fig. 31: Discarding Bolts Courtesy of FORD MOTOR CO.

11. Lower the subfram subframee approximately approximately 3-4 inches inches to gain access access to the stabili stabilizer zer bar bracket bracket insulators insulators.. 12. Remove the four four bolts bolts and the stabili stabilizer zer bar and links. links.



Fig. 32: Removing Bolts And Stabilizer Bar And Links Courtesy of FORD MOTOR CO.

13. Position Position the dash opening opening weather weather seal aside. aside. Remove Remove and discard discard the pinch bolt. bolt. Disconnect Disconnect the intermediate steering shaft.



Fig. 33: Disconnecting Intermediate Steering Shaft


Courtesy of FORD MOTOR CO.

14. Remove and and discard discard the tie strap. strap. Positi Position on the heat heat shield shield aside. aside. 15

Remo Remove ve the the nut nuts. s.


Courtesy of FORD MOTOR CO.

14. Remove and and discard discard the tie strap. strap. Positi Position on the heat heat shield shield aside. aside. 15. 15. Remo Remove ve the the nut nuts. s.



Fig. 34: Positioning Heat Shield Aside Courtes Courtes of FORD FORD MOTOR MOTOR CO. CO.


16. Disconnect Disconnect the the power steering steering lines. lines. Remove Remove and discard discard the seals. seals.


16. Disconnect Disconnect the the power steering steering lines. lines. Remove Remove and discard discard the seals. seals.

Fig. 35: Disconnecting Power Steering Lines Courtesy of FORD MOTOR CO.

17. Remove Remove the the screw. screw. Posit Position ion the the bracket bracket asi aside. de.



Fig. 36: Positioning Bracket Aside Courtesy of FORD MOTOR CO.

18. Rotate the steering steering gear and remove remove it it through through the LH wheel well. well. Installation

NOTE:

New Te Teflon( flon(R R) se seals must must be insta installe lled d any any time time the the line lines s are are discon disconne necte cted d from from the steering g ear. ear.

1. Using the the special special tool, instal installl new seals seals (388898-S) (388898-S) on on the power steerin steering g lines.

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2003 FORD WINDSTAR Service Repair Manual.pdf

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