Ford Freestar, Monterey 2004-2006

Removal & Installation

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NOTE
This procedure requires Teflon® Seal Installer Set 211-D027 (D90P-3517) or equivalent.


WARNING
When repairing the power steering system, be careful to avoid the entry of contaminants or premature failure of the power steering components can result.

  1. Remove the cowl panel grille, as follows:
    1. Remove the 2 windshield wiper arm nuts.
    2.  
    3. Remove the LH and RH windshield wiper arms.
    4.  
    5. Remove the 4 cowl panel grille push pins.
    6.  
    7. Remove the cowl panel grille. Disconnect the washer hose.
    8.  

  2.  
  3. Remove the engine accessory drive belt, as outlined in Engine Mechanical.
  4.  
  5. Using a suitable suction device, drain the power steering fluid reservoir.
  6.  
  7. Release the power steering fluid reservoir-to-power steering pump hose lower clamp and disconnect the hose.
  8.  
  9. Disconnect the power steering pressure line-to-pump fitting. To install, tighten to 65 Nm (48 lb-ft).
    NOTE
    When disconnecting the power steering pressure line-to-pump fitting, a new Teflon® seal must be installed.

  10.  
  11. Remove and discard the Teflon® seal.
  12.  
  13. Remove the 4 power steering pump bolts, then remove the power steering pump.

    Click image to see an enlarged view

    Fig. View of the power steering fluid reservoir-to-power steering pump hose lower clamp (1), power steering fluid reservoir-to-power steering pump hose (2), power steering pressure line-to-pump fitting (3), Teflon® seal (4), power steering pump bolts (5) and power steering pump (6). Note: The power steering pump pulley has been removed for clarity.

  14.  

To install:

  1. Install the power steering pump and tighten the bolts to 18 ft. lbs. (25 Nm).
  2.  
  3. Using the special tool, install a new Teflon® seal on the power steering pressure line-to-pump fitting.

    Click image to see an enlarged view

    Fig. Using a suitable Teflon® seal installer tool, install a new Teflon® seal on the power steering pressure line-to-pump fitting

  4.  
  5. Connect the power steering pressure line-to-pump fitting. Tighten to 48 ft. lbs. (65 Nm).
  6.  
  7. Connect the power steering fluid reservoir-to-power steering pump hose and secure with the lower clamp.
  8.  
  9. Install the engine accessory drive belt, as outlined in Engine Mechanical.
  10.  
  11. Install the cowl panel grille, as follows:
    1. Install the cowl panel grille.
    2.  
    3. Connect the washer hose.
    4.  
    5. Install the 4 cowl panel grille push pins.
    6.  
    7. Install the LH and RH windshield wiper arms.
    8.  
    9. Cycle and park the windshield wipers.
    10.  
    11. Install the 2 windshield wiper arm nuts and tighten to 18 ft. lbs. (25 Nm).
    12.  

  12.  
  13. Fill the power steering system, as outlined under Bleeding.
  14.  

 
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