Ford Falcon. Manual — part 87
211-02-1 Power
Steering 211-02-1
SECTION : 211-02 Power Steering
VEHICLE APPLICATION : 2003.0 BA Falcon
CONTENTS
PAGE
SPECIFICATIONS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211-02-2
DESCRIPTION AND OPERATION
Power Steering Pump — I6 . . . . . . . . . . . . . . . . . . . . . . . . ...211-02-3
Power Steering Pump — V8 . . . . . . . . . . . . . . . . . . . . . . . . ..211-02-3
Pump
Identification
. . . . . . . . . . . . . . . . . . . . . . . . . . . ...211-02-4
DIAGNOSIS AND TESTING
Power Steering Pump — I6 . . . . . . . . . . . . . . . . . . . . . . . . ...211-02-5
Symptom
Chart
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211-02-5
GENERAL PROCEDURES
Start of Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211-02-15
Remedying Pump Noise . . . . . . . . . . . . . . . . . . . . . . . . . ..211-02-15
Purging Power Steering System of Air . . . . . . . . . . . . . . . . . . . . 211-02-15
Flushing Power Steering Pump (I6) . . . . . . . . . . . . . . . . . . . . . .211-02-15
Flushing Power Steering Gear (I6) . . . . . . . . . . . . . . . . . . . . . ..211-02-15
REMOVAL AND INSTALLATION
Steering Gear Cylinder Pipe and O — Ring Seals . . . . . . . . . . . . . . . ..211-02-17
Steering Gear Spool Shaft Seals and Bearings . . . . . . . . . . . . . . . . ..211-02-17
Power Steering Pump (I6) . . . . . . . . . . . . . . . . . . . . . . . . . 211-02-21
Power Steering Pump (V8) . . . . . . . . . . . . . . . . . . . . . . . . ..211-02-22
Power Steering Pump Pulley (V8) . . . . . . . . . . . . . . . . . . . . . ...211-02-23
Steering Gear — I6 . . . . . . . . . . . . . . . . . . . . . . . . . . . ..211-02-23
Steering Gear — V8 . . . . . . . . . . . . . . . . . . . . . . . . . . . .211-02-24
Steering Gear Bushing and Sleeve . . . . . . . . . . . . . . . . . . . . . .211-02-24
Drive Belt (I6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...211-02-25
Quick Connect Power Steering Fitting (I6) . . . . . . . . . . . . . . . . . . ..211-02-25
Power Steering Lines (I6) . . . . . . . . . . . . . . . . . . . . . . . . . 211-02-26
Power Steering Lines (V8) . . . . . . . . . . . . . . . . . . . . . . . . ...211-02-27
DISASSEMBLY AND ASSEMBLY
Resorvoir Assembly (I6) . . . . . . . . . . . . . . . . . . . . . . . . . ...211-02-29
Resorvoir Assembly (V8) . . . . . . . . . . . . . . . . . . . . . . . . . .211-02-29
Control Valve Assembly (I6) . . . . . . . . . . . . . . . . . . . . . . . . 211-02-29
Drive Shaft Seal (I6) . . . . . . . . . . . . . . . . . . . . . . . . . . . .211-02-30
Hydraulic Pump Assembly (I6) . . . . . . . . . . . . . . . . . . . . . . . .211-02-31
211-02-2 Power
Steering 211-02-2
SPECIFICATIONS
General Specifications
Description
Nm
Description
Specification
Fitting
65
Lubrication
Connector to Discharge
30
Power Steering Hydraulic ESN M2C 134 D (Mobil
Power steering pump (V8) lower bolt
20-30
System
424 or equivelant)
Power steering pump (V8) upper bolts
20-30
Ford R1-424
0.95 litre approximately
(total system)
Power Steering Rack and ESA M1 C 75B
Pinion (Shell Alvania L
50 grams
PRO)
Pump Capacity
0.6 litre
Multi-Purpose Grease
ESB-M1C93-B and
DOAZ-19584-AA
ESR-M1C159-A
MERCON®
MERCON®
Multi-Purpose ATF
XT-2-QDX
Power Steering Gear
Steering Gear Constant
47.8mm/rev
Ratio
Steering Ratio (on
18.9:1
centre)
Turns of Steering Wheel
3.09
(Stop to Stop)
Preload: Maximum
5 Nm
allowable over full travel
of rack
Torque Specifications
Description
Nm
Rack Pad Locknut
75
Tube Nuts (Feed Pipes)
20
Tube Nuts (Pressure and Return)
35
Tie Rod Ball Housing
85
Pressure Switch
14
Steering Gear to Sub-frame
80
Pinion Lower Retaining Nut
40
Pinion Lower Screw Plug
60
Reservoir to Pump
50
Pump to Mounting Brackets (V8)
50
Pump to Mounting Brackets (I6)
25
Mounting Brackets to Cyl. Head (I6
47
-m8)
Mounting Brackets to Cyl. Head (I6
23
-m10)
Mounting Brackets to Cyl. Head (V8
47
-7/6)
Idler Pulley Locknut
47
Idler Pulley Bracket to Block
40
Pressure Hose Tube Nut
24
Return Hose Clamp Screw
30
Discharge Fitting to Pump
5
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211-02-3 Power
Steering 211-02-3
DESCRIPTION AND OPERATION
Power Steering Pump — I6
The power steering pump is a constant displacement
vane type providing hydraulic pressure for the
steering system. The housing and internal parts of the
pump are inside the reservoir so the pump parts
operate submerged in oil. The reservoir is sealed
against the pump housing, leaving the housing face
and the shaft hub exposed.
The drive shaft is fitted with a pulley and is belt driven
from the crankshaft. The rotor is loosely splined to the
drive shaft and secured with a retaining ring. Ten
vanes are mounted in radial slots in the rotor.
An identification label showing the pump model
number is located on the outboard side of the pump
reservoir.
Power Steering Pump — V8
NOTE: On early build 4.6L and 5.4L engines there are
four bolts mounting the power steering pump to the
engine block. The fourth bolt on earlier builds may be
discarded upon the replacement of the power steering
pump.
The CIII power steering pump has the following
features:
It is a belt-driven, vane-type, power steering
pump.
It is mounted directly to the engine block by three
bolts.
The power steering pump is replaced as an
assembly.
An identification tag attached to the power
steering pump indicates the model number and
bar code. Refer to the identification tag when the
pump replacement is required.
The power steering pump uses a quick connect
fitting for the power steering pressure hose.
The power steering fluid reservoir is mounted to
the front of the engine bay on top of the shroud.
G37361 en
211-02-4 Power
Steering 211-02-4
DESCRIPTION AND OPERATION (Continued)
System View — I6
Item
Description
1
Steering Gear
2
Power Steering Pump
3
Power Steering Return Hose
4
Power Steering Fluid Cooler
5
Press & Return Hose Assy
Pump Identification
CAUTION: Always use the ID code when
ordering service parts.
An identification tag is attached to the valve housing.
Item
Description
1
Model Code
2
For Manufacturing Purposes Only
3
Day
4
Shift
5
Year
6
Month
G37361 en
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