Ford Excursion, Expedition, Lincoln Navigator 2000-2005

Removal & Installation

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WARNING
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. Remove the engine cooling fan, as outlined in the Engine Mechanical Section.
  2.  
  3. Remove the power steering pump pulley, as follows:
    1. Rotate the tensioner clockwise and remove the engine accessory drive belt from the power steering pump pulley.
    2.  
    3. Remove the air cleaner intake pipe.
    4.  
    5. Using the special tool, remove the power steering pump pulley.

      Click image to see an enlarged view

      Fig. Use the special tool remove the power steering pump pulley

    6.  

  4.  
  5. Disconnect the clamp and remove the supply hose. Allow the fluid to drain into a suitable container.
  6.  
  7. Remove the pressure line bracket-to-engine nut.
  8.  
  9. Disconnect the pressure line-to-pump fitting. Discard the Teflon® seal.
  10.  
  11. Remove the 3 pump bolts.
  12.  
  13. Disconnect the harness retainer and remove the power steering pump.

    Click image to see an enlarged view

    Fig. Remove the bolts, detach the harness retainer and remove the power steering pump

  14.  

To install:

  1. Installation of the power steering pump is the reverse of the removal procedure. Please note the following:
    1. Tighten the power steering pump mounting bolts to 18 ft. lbs. (25 Nm).
    2.  
    3. Use Teflon® Seal Installer Set 211-D207 (D90P-3517-A) or equivalent to install a new Teflon® seal on the pressure line-to-pump fitting.
    4.  
    5. Tighten the pressure line-to-pump fitting to 48 ft. lbs. (65 Nm).
    6.  
    7. Tighten the pressure line bracket-to-engine nut to 30 ft. lbs. (40 Nm).

      Click image to see an enlarged view

      Fig. Using the special tool, install a new Teflon® seal on the pressure line-to-pump fitting

    8.  

  2.  
  3. Install the power steering pump pulley, as follows:
    WARNING
    If the pulley has been removed and installed twice, install a new power steering pump pulley.

    1. Using the special tool, install the power steering pump pulley. Inspect the pulley for paint marks in the web area near the hub. If there are 2 paint marks, install a new pulley. If there is 1 paint mark or none at all, use a paint pencil to mark the web area of the pulley near the hub.
    2.  
    3. Install the air cleaner element.
    4.  
    5. Rotate the tensioner clockwise and install the engine accessory drive belt on the power steering pump pulley.
    6.  

  4.  
  5. Fill the power steering system.
  6.  

CII Power Steering Pump



  1. Remove the power steering pump pulley, as follows:
    1. If equipped with A/C, rotate the tensioner clockwise and remove the belt from the power steering pump pulley. If not equipped with A/C, rotate the tensioner counterclockwise and remove the belt from the power steering pump pulley.
    2.  
    3. Using Power Steering Pump Pulley Removal tool no. 211-016 (T69L-10300-B), or equivalent, remove the power steering pump pulley.
      NOTE
      Replacement of the power steering pump pulley is necessary after being removed and installed two times.

    4.  

  2.  
  3. Loosen the clamps and remove the air cleaner outlet tube.
  4.  
  5. Remove the inlet air tube:
    1. Loosen the clamp.
    2.  
    3. Detach the ducts from the charge air cooler and remove the inlet air tube.
    4.  

  6.  
  7. Remove the return hose.
  8.  
  9. Place a pan under the power steering pump and drain the pump.
  10.  
  11. Disconnect the power steering high-pressure line.
  12.  
  13. Remove the bolts and detach the pump from the bracket.
  14.  
  15. Disconnect the power steering oil cooler return hose and remove the pump.
  16.  

To install:

  1. To install, reverse the removal procedure.
  2.  
  3. Tighten the power steering pump mounting bolts to 60 ft. lbs. (80 Nm).
    1. When connecting a fitting with a Teflon® seal, a new ring must be installed. Using Teflon® Seal Installer Stet 211-D027, or equivalent special tool, install a Teflon® seal over a fitting.

      Click image to see an enlarged view

      Fig. Using the special tool, install a new Teflon® seal on the pressure line-to-pump fitting

    2.  

  4.  
  5. Fill and leak check the power steering system.
  6.  

CIII Power Steering Pump




WARNING
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. Remove the power steering pump pulley.
    1. On 6.0L engines, remove the engine cooling fan.
    2.  
    3. If equipped with A/C, rotate the tensioner clockwise and remove the belt from the power steering pump pulley. If not equipped with A/C, rotate the tensioner counterclockwise and remove the belt from the power steering pump pulley.
    4.  
    5. On 5.4L and 6.8L engines, raise and safely support the vehicle.
    6.  
    7. Using Power Steering Pump Pulley Removal tool no. 211-016 (T69L-10300-B), or equivalent, remove the power steering pump pulley.
    8.  
    9. Inspect the pulley for paint marks in the web area near the hub. If there are two paint marks, discard the pulley. If there is no paint or one paint mark, use a paint pencil to mark the web area of the pulley near the hub.
      NOTE
      Replacement of the power steering pump pulley is necessary after being removed and installed two times.

    10.  

  2.  
  3. Disconnect the pressure line and return hose.
  4.  
  5. Remove the bolts and the power steering pump.
  6.  

To install:

  1. Installation is the reverse of the removal procedure. Tighten the power steering pump mounting bolts to 19 ft. lbs. (26 Nm). Tighten the pressure line fitting to 26 ft. lbs. (35 Nm).
    1. When connecting a fitting with a Teflon® seal, a new ring must be installed. Using Teflon® Seal Installer Stet 211-D027, or equivalent special tool, install a Teflon® seal over a fitting.

      Click image to see an enlarged view

      Fig. Using the special tool, install a new Teflon® seal on the pressure line-to-pump fitting

    2.  

  2.  
  3. Fill and leak check the system.
  4.  

 
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