Ford Falcon. Manual — part 94

211-02-29 Power

Steering 211-02-29

DISASSEMBLY AND ASSEMBLY

3. Remove the power steering fluid reservoir from its

Resorvoir Assembly (I6)

support bracket.

NOTE: Take the following precautions when servicing

the power steering pump reservoir:

Use a clean work bench and tools.
Plug the inlet and outlet openings of the pump

with plugs or masking tape.
Thoroughly clean the exterior of the pump with

solvent.

Disassembly
1. Remove pump assembly from vehicle, if

necessary for access (Refer to Power Steering

Pump Removal in this section).

2. Disconnect retaining clips from reservoir assembly

and housing.

Assembly
1. To install, reverse the removal procedure.
2. Fill and leak check the system.

Control Valve Assembly (I6)

Disassembly

3. Remove reservoir from housing.
4. Remove O-ring seal from reservoir.

Assembly
1. Lubricate new O-ring with power steering fluid.

Install O-ring seal to reservoir.

2. Connect reservoir assembly to housing.
3. Install retaining clips to reservoir and housing.

Item

Description

4. Install pump assembly to vehicle, if removed.

1

Housing ASM, HYD Pump

2

Spring, Flow Control

Resorvoir Assembly (V8)

3

Valve ASM, Control

Disassembly

4

Seal, O-Ring

1. Drain the power steering fluid reservoir.

5

Fitting, O-Ring Union

2. Disconnect the power steering warm drive hoses. 1. Remove pump assembly from vehicle, if

1. Loseen and move the power steering hose

necessary for access (Refer to Power Steering

clamps.

Pump Removal in this section).

2. Disconnect the power steering return hose

2. Remove O-ring union fitting and O-ring.

and the power steering reservoir pump hose.

3. Remove control valve assembly.
4. Remove flow control spring.

Assembly
1. Install flow control spring.
2. Install control valve assembly.
3. Install O-ring on fitting.

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211-02-30 Power

Steering 211-02-30

DISASSEMBLY AND ASSEMBLY (Continued)

4. Install fitting into hydraulic pump housing

assembly and tighten to 75Nm.

5. Install pump assembly to vehicle, if removed.

Drive Shaft Seal (I6)

Special Tool(s)

Shaft Oil Seal Installer

J 7728

Disassembly
1. Remove P/S Pump pulley using tool 7185.
2. Remove pump assembly from vehicle, if

necessary for access (Refer to Power Steering

Pump Removal in this section).

Item

Description

Item

Description

7

Vane

1

Pin, Pump Ring Dowel

8

Rotor, Pump

2

Shaft, Drive

9

Ring, Shaft Retaining

3

Housing ASM, HYD Pump

10

Plate, Pressure

4

Seal, Drive Shaft

11

Seal, O-Ring

5

Plate, Thrust

12

Spring, Pressure Plate

6

Ring, Pump

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211-02-31 Power

Steering 211-02-31

DISASSEMBLY AND ASSEMBLY (Continued)

Item

Description

Hydraulic Pump Assembly (I6)

13

Seal, O-Ring

Special Tool(s)

14

Cover, End

15

Ring, Retaining

Shaft Oil Seal Installer

J7728

3. Protect drive shaft with shim stock.

NOTE: The following precautions must be observed

when servicing the power steering pump:

Use a clean work bench and tools.
Thoroughly clean the exterior of the unit with

solvent. Drain as much fluid from the pump as

possible.
If only the reservoir is to be removed, clean as

outlined.
Do not use cleaning solvents on the seal.

Item

Description

Disassembly

1

Chisel

1. Disassemble retaining ring using punch in access

2

Shaft Drive

hole.

3

Shim Stock

4

Housing ASM, HYD Pump

5

Seal Drive Shaft

4. Remove seal and discard (Use small chisel to cut

drive shaft seal).

Assembly
1. Install new drive shaft seal (lubricated with power

steering fluid, using tool J 7728

).

Item

Description

1

Punch

2

Access Hole

3

Ring Retaining

2. Disassemble internal components of pump from

pump housing by gentle pushing on drive shaft.

Components should include pressure plate

subassembly consisting of:

2. Install pump assembly to vehicle, if removed.

End cover
O-ring seal
Pressure plate spring
Pressure plate
Drive shaft subassembly consisting of:

Pump rotor

Thrust plate

Drive shaft

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211-02-32 Power

Steering 211-02-32

DISASSEMBLY AND ASSEMBLY (Continued)

Shaft retaining ring and pump ring and

3. Install thrust plate and pump rotor to drive shaft.

vanes.

3. Remove O-ring from pump housing.
4. Remove dowel pins.
5. Remove drive shaft seal.
6. Remove end cover (pressure plate spring) and

O-ring from pressure plate.

7. Remove pump ring (and vanes) from drive shaft

subassembly.

8. Remove shaft retaining ring (from drive shaft).
9. Remove pump rotor (and thrust plate) from drive

shaft.

Assembly
NOTE: Clean all parts in power steering fluid, then dry Item

Description

parts.

1

Shaft Drive

Inspect the following parts

2

Plate, Thrust

Pressure plate

3

Rotor, Pump

Pump ring

4

Ring, Shaft Retaining

Vanes

4. Install new shaft retaining ring onto drive shaft.

Thrust plate

5. Install drive shaft subassembly into pump

Drive shaft

housing.

For scoring, pitting or chatter marks. If noted replace

6. Install vanes into pump rotor.

appropriate parts.

7. Install pump ring (with holes positioned correctly

1. Lubricate new drive shaft seal with power steering

onto dowel pins in pump housing.

fluid and assemble drive shaft seal (into pump

housing) with tool J 7728.

Item

Description

1

Rotor, Pump

2. Install pump ring dowel pins into pump housing.

2

Ring, Pump

8. Lubricate new O-ring with power steering fluid.

Install O-ring into groove in pump housing.

9. Assemble pressure plate.
10. Assemble pressure plate spring.
11. Lubricate new O-ring (with power steering fluid).

Assemble O-ring into end cover.

12. Lubricate outer edge of end cover with power

steering fluid.

13. Press end cover into pump housing.

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