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

Specification

Fitting

Lubrication

Connector to Discharge

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®

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

Rack Pad Locknut

Tube Nuts (Feed Pipes)

Tube Nuts (Pressure and Return)

Tie Rod Ball Housing

Pressure Switch

Steering Gear to Sub-frame

Pinion Lower Retaining Nut

Pinion Lower Screw Plug

Reservoir to Pump

Pump to Mounting Brackets (V8)

Pump to Mounting Brackets (I6)

Mounting Brackets to Cyl. Head (I6

-m8)
Mounting Brackets to Cyl. Head (I6

-m10)
Mounting Brackets to Cyl. Head (V8

-7/6)
Idler Pulley Locknut

Idler Pulley Bracket to Block

Pressure Hose Tube Nut

Return Hose Clamp Screw

Discharge Fitting to Pump

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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.

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211-02-4 Power

Steering 211-02-4

DESCRIPTION AND OPERATION (Continued)

System View — I6

Item

Description

Steering Gear

Power Steering Pump

Power Steering Return Hose

Power Steering Fluid Cooler

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

Model Code

For Manufacturing Purposes Only

Day

Shift

Year

Month

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