Steering

Steering Wheel

REMOVAL & INSTALLATION

Remove the air bag module retaining bolt covers
Remove the air bag module retaining bolts
Lift the air bag module from the steering wheel and ...
... detach the connectors on the air bag module and remove the module
Always carry a live air bag module with the bag and trim cover facing away from your body
Always place an air bag module on a table or other flat surface with the bag and trim cover pointing up
Remove the steering wheel retaining bolt and ...
... install a suitable puller onto the steering wheel to remove the wheel
CAUTION
The Supplemental Inflatable Restraint (SIR) system must be disarmed before performing service around SIR system components or SIR system wiring. Failure to do so may cause accidental deployment of the air bag, resulting in unnecessary SIR system repairs and/or personal injury.

Before proceeding, make sure that a new steering wheel retaining bolt is available. Once removed the bolt loses its torque holding ability or retention capability and must not be reused.

  1. Make sure that the front wheels are in the straight-ahead position.
  2. Disconnect the negative battery cable(s).
  3. Wait at least 1 minute before proceeding with the service procedure. This is the time required for the backup power supply to deplete its stored energy.
  4. Remove the air bag module retaining bolt covers.
  5. Remove air bag module retaining bolts and lift the air bag module from the steering wheel.
  6. Detach the air bag sliding contact, horn and if equipped, the speed control electrical harness connectors and remove the air bag module.
CAUTION
When carrying a live air bag, make sure the air bag and trim cover are pointed away from the body. In the unlikely event of an accidental deployment, the bag will then deploy with minimal chance if injury. When placing a live air bag on a bench or other surface, always face the bag and trim cover up, away from the surface. This will reduce the motion of the module if it is accidentally deployed.
  1. Remove the steering wheel retaining bolt and discard.
  2. Install Steering Wheel Puller T67-3600-A or equivalent and loosen the steering wheel from the steering column shaft.
  3. Remove the steering wheel while routing the wires from the air bag sliding contact through the steering wheel.

To install:

If a new air bag sliding contact is being installed, remove the plastic lock tool after the intermediate shaft is connected to the steering gear.

  1. Make sure the vehicle's front wheels are in the straight-ahead position.
  2. Route the air bag sliding contact wire harness through the steering wheel opening at the three o'clock position. Position the steering wheel on the steering shaft so that the alignment marks on the wheel and shaft are aligned. Be sure the air bag sliding contact wiring is not pinched.
  3. Install a new steering wheel retaining bolt and tighten the bolt to 23-33 ft. lbs. (31-48 Nm) on the 1997-98 F-250HD, F-350 and F-Super Duty and to 23-32 ft. lbs. (31-44 Nm) on all other models.
  4. Connect the wire connectors for the horn, speed control and air bag module then position the air bag module on the steering wheel. Install and tighten the 4 air bag module retaining nuts to 35-50 inch lbs. (4.0-5.6 Nm) on 1997-98 F-250HD, F-350 and F-Super Duty models. Tighten the two air bag module retaining screws to 89-115 inch lbs. (10-13 Nm) on all other models.
  5. Connect both battery cables, negative cable last.
  6. Prove out the air bag system by turning the ignition key to the RUN position and visually monitoring the air bag indicator lamp in the instrument cluster. The indicator lamp should illuminate for approximately 6 seconds and then turn off. If the indicator lamp does not illuminate, stays on, or flashes at any time, a fault has been detected by the air bag diagnostic monitor.
  7. Check the steering wheel, horn and steering column for proper operation.
  8. Road test the vehicle and check the speed control for proper operation.

Multi-Function Switch

REMOVAL & INSTALLATION

1997-98 F-250HD, F-350 and F-SuperDuty

  1. Disconnect the negative battery cable.
  2. Remove the 4 retaining screws from the lower column shroud and remove the upper and lower shrouds.
  3. Remove the 2 retaining screws from the multi-function switch and unplug the 2 wiring connectors.
  4. Remove the switch.

To install:

  1. Install the multi-function switch.
  2. Tighten the 2 retaining screws and attach the 2 electrical connectors.
  3. Install the upper and lower column shrouds. Tighten the 4 retaining screws.
  4. Connect the negative battery cable.

F-150, F-250, Expedition, Navigator and 1999-00 Super Duty Models

Turn the ignition switch to the RUN position and push the lock cylinder release pin with a suitable punch while ...
... pulling out the lock cylinder
Remove 3 steering column shroud retaining screws and ...
... remove the upper and ...
... lower steering column shrouds
Remove the switch retaining screws, lift the switch assembly up and ...
... detach the switch electrical connectors to remove the switch
  1. Disconnect the negative battery cable.
  2. Remove the ignition key and tumbler as follows:
    1. Turn the ignition switch to the RUN position.
    2. Push the lock cylinder release pin with a suitable punch while pulling out the lock cylinder.
  3. If equipped, twist off the tilt wheel handle and remove.
  4. Remove 3 steering column shroud retaining screws and remove the upper and lower shrouds.
  5. Remove 2 self-tapping screws that retain the combination switch to the steering column casting. Disengage the switch from the casting.
  6. Detach the electrical connectors, being careful not to damage the locking tabs and the shift position indicator cable.

To install:

  1. Connect the combination switch electrical harness connectors ensuring that the connectors are fully engaged. The wiring for the switch is to be routed under the shift position indicator cable.
  2. Install the combination switch with 2 self-tapping screws. Tighten to 19-25 inch lbs. (2-3 Nm).
  3. Install the upper and lower steering column shrouds. Install the retaining screws and tighten to 9 inch lbs. (1 Nm).
  4. If equipped, install the tilt wheel handle ad tighten to 44 inch lbs. (5 Nm).
  5. Install the ignition key and tumbler assembly.
  6. Connect the negative battery cable.
  7. Check the steering column and combination switch for proper operation.

Ignition Switch

REMOVAL & INSTALLATION

  1. Disconnect the negative battery cable.
  2. Remove the steering column shroud and lower the steering column.
  3. Detach the ignition switch electrical harness connector.
  4. Remove 2 nuts retaining the ignition switch to the steering column housing.
  5. Lift the ignition switch upward to disengage the actuator rod from the switch and remove the switch.

To install:

When installing the ignition switch, both the locking mechanism at the top of the column and the switch itself must be in theLOCK position for correct adjustment. To hold the mechanical parts of the column in the LOCK position, move the shift lever into PARK (with automatic transmissions) or REVERSE (with manual transmissions), turn the key to the LOCK position, and remove the key. New replacement switches, when received, are already pinned in the LOCK position by a metal shipping pin inserted in a locking hole on the side of the switch.

  1. Engage the actuator rod in the ignition switch.
  2. Place the ignition switch on the steering column housing and loosely install 2 retaining nuts.
  3. Move the switch up or down along the column to locate the mid-position of the actuator rod lash, then tighten the retaining nuts to 47-64 inch lbs. (5-7 Nm).
  4. Raise the steering column into position at instrument panel. Install steering column shroud.
  5. Connect the negative battery cable.
  6. Remove the locking pin, connect the battery cable, and verify that the engine will only crank in PARK and NEUTRAL.Also check to make certain that the start circuit cannot be actuated in the DRIVE and REVERSE positions.

Ignition Lock Cylinder

REMOVAL & INSTALLATION

With Functional Lock Cylinder

Turn the ignition switch to the RUN position and push the lock cylinder release pin with a suitable punch while ...
... pulling out the lock cylinder
  1. Disconnect the negative battery cable.
  2. Detach the key warning chime connector.
  3. Turn the key to the RUN position.
  4. Place a 1/8 in. wire, pin, or small drift punch into the upper steering column shroud under the lock cylinder. Depress the retaining pin while pulling the lock cylinder out of the column housing.

To install:

  1. Install the lock cylinder by turning the key to the RUN position and depressing the retaining clip.
  2. Insert the lock cylinder until it is fully seated and aligned with the interlocking washer.
  3. Turn the key to the OFF position, allowing the retaining pin to properly seat.
  4. Install the 2 shroud halves and retaining screws.
  5. Connect the negative battery cable.
  6. Check for proper starting in PARK and NEUTRAL.

Non-Functional Lock Cylinder

Drilling out the lock retaining pin

Click to enlarge

Breaking the cap away from the lock cylinder

Click to enlarge

This procedure should be used when the lock cylinder cannot be rotated due to a lost or broken key, or damage to the cylinder prohibiting the insertion of a new key.

  1. Disconnect the negative battery cable.
CAUTION
Follow the proper procedure to disarm the air bag, if equipped.
  1. Remove the horn assembly or air bag.
  2. Remove the steering wheel.
  3. Remove the air bag clockspring, if equipped with air bag.
  4. With a pair of pliers, twist the cap off the lock cylinder.
  5. Through the access hole in the lower column shroud, use a small center punch and then with an 1/8 in. drill bit, drill out the retaining clip. Be careful not to drill deeper than 1/2 in.
  6. Using a 3/8 in. drill bit, drill down the middle of the lock cylinder about 1 3/4 inches until the cylinder breaks away from the housing.
  7. Remove the lock cylinder and clean out all metal shavings from the housing. Inspect the housing and replace if damaged.

To install:

  1. Install the lock drive gear, washer and retainer, if necessary.
  2. Install the lock cylinder by turning the key to the RUN position and depressing the retaining clip.
  3. Insert the lock cylinder until it is fully seated and aligned with the interlocking washer.
  4. Turn the key to the OFF position. this allows the retaining pin to properly seat.
  5. Connect the key warning chime electrical connector.
  6. Install the air bag clockspring if equipped with an air bag. Make sure that the clockspring is properly aligned.
  7. Install the steering wheel.
  8. Install the air bag or horn assembly, as equipped.
  9. Connect the negative battery cable.
  10. Check for proper starting in PARK and NEUTRAL.

Steering Linkage

REMOVAL & INSTALLATION

Steering linkage used on the 4-wheel drive F-350

Click to enlarge

Steering linkage used on F-Super Duty chassis/cab

Click to enlarge

Steering linkage for F-Super Duty stripped chassis and motor home chassis

Click to enlarge

Pitman Arm

Pitman arm removal

Click to enlarge

EXCEPT F-SUPER DUTY STRIPPED CHASSIS AND MOTOR HOME CHASSIS
  1. Place the wheels in a straight-ahead position.
  2. Disconnect the drag link at the Pitman arm. You'll need a puller such as a tie rod end remover.
  3. Remove the Pitman arm-to-gear nut and washer.
  4. Matchmark the Pitman arm and gear housing for installation purposes.
  5. Using a 2-jawed puller, remove the Pitman arm from the gear.
  6. Installation is the reverse of removal. Align the matchmarks when installing the Pitman arm. Tighten the Pitman arm nut to 170-230 ft. lbs. (230-312 Nm); torque the drag link ball stud nut to 50-75 ft. lbs. (68-102 Nm), advancing the nut to align the cotter pin hole. Never back off the nut to align the hole.
F-SUPER DUTY STRIPPED CHASSIS MOTOR HOME CHASSIS
  1. Matchmark the Pitman arm and sector shaft.
  2. Disconnect the drag link from the Pitman arm.
  3. Remove the bolt and nut securing the Pitman arm to the sector shaft.
  4. Using a 2-jawed gear puller, remove the Pitman arm from the sector shaft.

To install:

  1. Aligning the matchmarks, slide the Pitman arm onto the sector shaft. If the arm won't slide on easily, use a cold chisel to spread the separation. NEVER HAMMER THE ARM ONTO THE SHAFT! Hammering on the arm will damage the steering gear!
  2. Install the nut and bolt. Tighten the nut to 220-300 ft. lbs. (298-407 Nm).
  3. Connect the drag link.

Drag Link

EXCEPT RUBBERIZED BALL SOCKET LINKAGE
  1. Place the wheels in a straight-ahead position.
  2. Remove the cotter pins and rust from the drag link and tie rod ball studs.
  3. Remove the drag link ball studs from the right-hand spindle and Pitman arm.
  4. Remove the tie rod ball studs from the left-hand spindle and drag link.
  5. Installation is the reverse of removal. Seat the studs in the tapered hole before tightening the nuts. This will avoid wrap-up of the rubber grommets during tightening of the nuts. Tighten the nuts to 70 ft. lbs. (95 Nm). Always use new cotter pins.
  6. Have the front end alignment checked.
RUBBERIZED BALL SOCKET LINKAGE
  1. Raise and support the front end on jackstands.
  2. Place the wheels in the straight-ahead position.
  3. Remove the nuts connecting the drag link ball studs to the connecting rod and Pitman arm.
  4. Disconnect the drag link using a tie rod end remover.
  5. Loosen the bolts on the adjuster clamp. Count the number of turns it take to remove the drag link from the adjuster.

To install:

  1. Installation is the reverse of the removal procedure. Install the drag link with the same number of turns it took to remove it. Make certain that the wheels remain in the straight-ahead position during installation. Seat the studs in the tapered hole before tightening the nuts. This will avoid wrap-up of the rubber grommets during tightening of the nuts. Tighten the adjuster clamp nuts to 40 ft. lbs. (54 Nm). Tighten the ball stud nuts to 75 ft. lbs. (102 Nm).
  2. Have the front end alignment checked.

Connecting Rod

  1. Raise and support the front end on jackstands.
  2. Place the wheels in the straight-ahead position.
  3. Disconnect the connecting rod from the drag link by removing the nut and separating the two with a tie rod end remover.
  4. Loosen the bolts on the adjusting sleeve clamps. Count the number of turns it takes to remove the connecting rod from the connecting rod from the adjuster sleeve and remove the rod.
  5. Installation is the reverse of removal. Install the connecting rod the exact number of turns noted during removal. Tighten the tie rod nuts to 40 ft. lbs. (54 Nm); the ball stud nut to 75 ft. lbs. (102 Nm).
  6. Have the front end alignment checked.

Tie Rod Ends

F-250HD/SD, F-350 and F-SUPERDUTY
  1. Raise and safely support the vehicle.
  2. Place the front wheels in a straight-ahead position.
  3. If necessary, remove the wheel and tire assembly.
  4. Remove the cotter pin and castellated nut from the tie rod end at the wheel spindle or steering knuckle, as equipped. Discard the cotter pin.
  5. Loosen the nuts on the adjusting sleeve clamps.
  6. Using Pitman Arm Puller T64P-3590-F, or equivalent, separate the tie rod end
  7. Remove the tie rod end from the adjusting sleeve. Count and record the number of turns required to remove the tie rod end from the adjusting sleeve for installation reference.

To install:

  1. Install the tie rod end to the adjusting sleeve the same number of turns noted during removal. Make sure that the adjuster clamps are in the correct position and do not to rub or bind against the frame or steering components.
  2. Keep the wheels straight ahead and install the tie rod end stud into the wheel spindle or steering knuckle, as equipped. Install the castellated nut and tighten to 51-73 ft. lbs. (70-100 Nm), then continue to tighten the castellated nut as needed to install a new cotter pin.
  3. Tighten the adjusting sleeve clamp nuts to 30-42 ft. lbs. (40-57 Nm).
  4. If removed, install the wheel and tire assembly. Torque the lug nuts to 100 ft. lbs. (135 Nm).
  5. Lower the vehicle.
  6. Check the alignment and adjust if not within specification.
  7. Road test the vehicle and check for proper steering system operation.
F-150, F-250, EXPEDITION AND NAVIGATOR
The tie rod end is attached to the steering knuckle by a nut and cotter pin
Remove the cotter pin and the ...
... castellated nut on the tie rod end
attach a suitable puller to the tie rod end and ...
... tighten down the forcing screw until ...
... tie rod end pops up out of the knuckle
Loosen the outer tie rod end jam nut and ...
... remove the tie rod end from the adjusting sleeve
Count the threads showing on the tie rod end and ...
... note it on the tie rod end for reassembly
  1. Raise and safely support the vehicle.
  2. Remove the wheel and tire assembly.
  3. Match mark the outer tie rod end to the adjusting sleeve and inner tie rod end for assembly reference.
  4. Remove the outer tie rod end cotter pin and castellated nut. Discard the cotter pin.
  5. Using Pitman Arm Puller T64P-3590-F or equivalent, separate the tie rod end from the wheel spindle or knuckle, as equipped.
  6. Loosen the outer tie rod end jam nut. Turn the tie rod end and remove counting the amount of turns for assembly reference.

To install:

  1. Install the new outer tie rod end by threading it into the adjusting sleeve the same amount of turns as the one removed. Do not tighten the jam nut at this point.
  2. Connect the outer tie rod end to the wheel spindle or knuckle, as equipped. Install the castellated nut and tighten to 55-75 ft. lbs. (77-104 Nm). Install a new cotter pin.
  3. Install the wheel and tire assembly. Torque the lug nuts to 83-112 ft. lbs. (113-153 Nm).
  4. Lower the vehicle.
  5. Check the toe adjustment and adjust if out of specification.
  6. Tighten the tie rod end jam nut to 55-75 ft. lbs. (77-104 Nm).
  7. Road test the vehicle and check the steering system for proper operation.

Inner Tie Rod End

F-150, F-250, EXPEDITION AND NAVIGATOR
  1. Raise and safely support the vehicle.
  2. Remove the wheel and tire assembly.
  3. Match mark the inner tie rod end to the adjusting sleeve for assembly reference.
  4. Remove the inner tie rod end cotter pin and castellated nut. Discard the cotter pin.
  5. Using Pitman Arm Puller T64P-3590-F or equivalent, separate the inner tie rod end from the drag link.
  6. Loosen the jam nut. Turn the inner tie rod end and remove counting the amount of turns for assembly reference.

To install:

  1. Install the new inner tie rod end by threading it into the sleeve the same amount of turns as the one removed. Do not tighten the jam nut at this point.
  2. Connect the inner tie rod end to the drag link and install the castellated nut. Tighten the nut to 55-75 ft. lbs. (77-104 Nm). Install a new cotter pin.
  3. Install the wheel and tire assembly. Torque the lug nuts to 83-112 ft. lbs. (113-153 Nm).
  4. Lower the vehicle.
  5. Check the toe adjustment and adjust if out of specification.
  6. Tighten the inner tie rod end jam nut to 55-75 ft. lbs. (77-104 Nm).
  7. Road test the vehicle and check the steering system for proper operation.

Power Steering Gear

REMOVAL & INSTALLATION

1997-98 F-250HD, F-350 and F-Super Duty Except Stripped Chassis and Motorhome

Removal/installation—1997-98 F-250HD, F-350 and F-Super Duty Except Stripped Chassis and Motorhome

Click to enlarge

  1. Raise and support the front end on jackstands.
  2. Place the wheels in the straight-ahead position.
  3. Place a drain pan under the gear and disconnect the pressure and return lines. Cap the openings.
  4. Remove the splash shield from the flex coupling.
  5. Disconnect the flex coupling at the gear.
  6. Matchmark and remove the Pitman arm from the sector shaft.
  7. Support the steering gear and remove the mounting bolts.
  8. Remove the steering gear. It may be necessary to work it free of the flex coupling.

To install:

  1. Place the splash shield on the steering gear lugs.
  2. Slide the flex coupling into place on the steering shaft. Make sure the steering wheel spokes are still horizontal.
  3. Center the steering gear input shaft with the indexing flat facing downward.
  4. Slide the steering gear input shaft into the flex coupling and into place on the frame side rail. Install the flex coupling bolt and torque it to 30-42 ft. lbs. (41-57 Nm).
  5. Install the gear mounting bolts and torque them to 65 ft. lbs. (88 Nm).
  6. Make sure that the wheels are still straight-ahead and install the Pitman arm. Tighten the nut to 170-288 ft. lbs. (230-390 Nm).
  7. Connect the pressure, then, the return lines. Tighten the pressure line to 25 ft. lbs. (34 Nm).
  8. Snap the flex coupling shield into place.
  9. Fill the steering reservoir.
  10. Run the engine and turn the steering wheel lock-to-lock several times to expel air. Check for leaks.

1997-98 F-Super Duty Stripped Chassis and Motorhomes

Steering gear installation on F-Super Duty motor home chassis models

Click to enlarge

Steering gear installation on F-Super Duty stripped chassis models

Click to enlarge

  1. Raise and support the front end on jackstands.
  2. Thoroughly clean all connections.
  3. Place a drain pan under the area.
  4. Disconnect the hydraulic lines at the gear. Cap all openings at once.
  5. Remove the retaining bolt and nut and disconnect the Pitman arm from the sector shaft.
  6. Remove the bolt and nut securing the input shaft and U-joint.
  7. Support the gear and remove the gear-to-frame bolts and nuts.

To install:

  1. Position the gear on the frame and install the bolts and nuts. Tighten the nuts to 150-200 ft. lbs. (203-271 Nm).
  2. Install the U-joint bolt and nut. Tighten the nut to 50-70 ft. lbs. (68-95 Nm).
  3. Install the Pitman arm.
CAUTION
Never hammer the Pitman shaft onto the sector shaft! Hammering will damage the gear. Use a cold chisel to separate the Pitman arm opening.
  1. Install the bolt and nut. Tighten the nut to 220-300 ft. lbs. (298-407 Nm).
  2. Connect the hydraulic lines, fill the reservoir, run the engine and check for leaks.

F-150, F-250, Expedition and Navigator

  1. Raise and safely support the vehicle.
  2. If equipped, remove 6 retaining bolts securing the skid plate and remove the skid plate.
  3. Remove 3 screws and 5 push clips retaining the lower radiator air deflector and remove.
  4. Remove the pitman arm (steering sector shaft arm) cotter pin and castellated nut from the drag link.
  5. Using Pitman Arm Puller T65P-3590-F or equivalent, separate the pitman arm from the drag link.
  6. Remove the dust cover from the steering shaft valve housing.
  7. Remove the intermediate shaft pinch bolt and slide the shaft off the steering gear input shaft.
  8. Disconnect the power steering pressure hoses at the steering gear.
  9. Remove 3 steering gear-to-frame rail retaining bolts and remove the steering gear.
  10. If replacing or servicing the steering gear, match mark the sector shaft arm to the sector shaft and remove the steering gear sector shaft arm retaining nut and lock washer. Remove the sector shaft arm using Pitman Arm Puller T65P-3590-F, or equivalent.

To install:

  1. If removed, install the steering gear sector shaft arm to the sector shaft aligning the match marks made during removal. Install the retaining nut and lock washer and tighten to 170-228 ft. lbs. (234-316 Nm).
  2. Mount the steering gear in position. Install 3 retaining bolts and tighten to 50-68 ft. lbs. (68-92 Nm).
  3. Connect the power steering pressure hoses to the steering gear using new seals, if necessary.
  4. Slide the intermediate shaft on the steering gear input shaft and install the shaft pinch bolt. Tighten the pinch bolt to 30-42 ft. lbs. (41-57 Nm).
  5. Install the dust cover over the steering shaft valve housing.
  6. Connect the pitman arm to the drag link. Install the castellated nut and tighten to 57-76 ft. lbs. (77-104 Nm). Install a new cotter pin.
  7. Install the radiator air deflector and secure with 3 retaining screws and 5 push clips.
  8. Install the skid plate and secure with 6 retaining bolts.
  9. Lower the vehicle.
  10. Fill and bleed the power steering system.
  11. Road test the vehicle and check the steering system for proper operation.

1999-00 F-Super Duty models except for Motorhome chassis

  1. Remove the air cleaner assembly.
  2. Disengage the steering coupling shield from the line fitting and slide upwards on the steering shaft.
  3. Make sure the steering column is locked.
  4. Remove the intermediate shaft-to-gear pinch bolt. Turn the steering wheel as necessary to access the bolt.
  5. Disconnect the power steering lines.
  6. Raise and support the vehicle.
  7. Remove the drag link cotter pin and nut and disconnect the drag link.
  8. Remove the bolts and the steering gear.
  9. Remove the steering gear sector shaft arm.

To install:

  1. The installation is the reverse of the removal.

1999-00 F-Super Duty Motorhome chassis

  1. Drain the power steering reservoir.
  2. Remove the steering shaft coupler pinch bolt.
  3. Slide the coupler upward and away from the steering gear.
  4. Disconnect the two power steering lines.
  5. Remove the steering link cotter pin and retaining nut.
  6. Remove the steering link from the steering gear sector shaft.
  7. Remove the three nuts and bolts and remove the steering gear.

To install:

  1. The installation is the reverse of the removal.

Power Steering Pump

REMOVAL & INSTALLATION

5.8L, 7.3L, and 7.5L Engines

EXCEPT F-SUPER DUTY STRIPPED CHASSIS AND MOTOR HOME MODELS
Power steering pump installation on the 5.8L engine

Click to enlarge

Power steering pump installation on the 7.5L EFI

Click to enlarge

  1. Disconnect the return line at the pump and drain the fluid into a container.
  2. Disconnect the pressure line from the pump.
  3. Loosen the pump bracket nuts and remove the drive belt.
  4. Remove the nuts and lift out the pump/bracket assembly.
  5. If a new pump or bracket is being installed, remove the pulley from the pump; use a press and adapters.

To install:

  1. Position the steering pump on the engine and install the mounting fasteners. Tighten the fasteners to the following specifications:
  1. Install the accessory drive belt.
  2. Attach the fluid lines to the pump, then bleed the hydraulic steering system.
F-SUPER DUTY STRIPPED CHASSIS AND MOTOR HOME MODELS
ZF Power steering pump installation on F-Super Duty motor home chassis

Click to enlarge

ZF Power steering pump installation on F-Super Duty stripped chassis

Click to enlarge

  1. Disconnect the pressure line from the pump and tie up the ends of both hoses in a raised position. Cap the openings.
  2. Loosen the pump pivot and adjusting bolts and remove the drive belt.
  3. Remove the bolts and lift out the pump.

To install:

  1. Install the pump in the vehicle.
  2. Install the pivot bolt and nut finger-tight.
  3. Install the accessory drive belt, then adjust the belt tension.
  4. Tighten the mounting (pivot and adjusting) bolts to 30-45 ft. lbs. (41-61 Nm).
  5. Connect the hoses, then refill the reservoir.
  6. Bleed the system, then run the engine and check for leaks.

4.2L, 4.6L, 5.4L and 6.8L Engines

  1. Remove the engine air cleaner assembly.
  2. Remove the accessory drive belt.
  3. Disconnect the power steering reservoir pump hose from the power steering pump and drain the fluid into a large catch pan.
  4. Disconnect the power steering pressure hose from the steering gear.
  5. Remove the 2 top power steering pump bolts.
  6. Raise and safely support the front of the vehicle on jackstands.
  7. Remove the 2 lower pump bolts and remove the power steering pump from the engine.
  8. Lower the vehicle.
  9. If necessary, remove the power steering pressure hose fitting from the pump by holding the pump in a vise.
  10. If necessary, remove the power steering pump pulley. Hold the Steering Pump Pulley Remover T69L-10300-B, or equivalent and rotate the forcing bolt to remove the pulley from the pump.

To install:

  1. If the pulley was removed, thread the forcing bolt into the power steering pump and turn the steering pump pulley replacer tool, or equivalent, to install the pump pulley.
  2. Install a new power steering Teflon® seal onto the pressure hose fitting by stretching the Teflon® seal over the Teflon® seal replacer set D90P-3517-A, or equivalent, until it is large enough to slip over the tube nut.
  3. Install the power steering pressure hose, then tighten the fitting to 20-30 ft. lbs. (27-41 Nm).
  4. Position the steering pump and loosely install the 4 mounting bolts.
  5. Tighten the 2 upper mounting bolts to 15-20 ft. lbs. (20-30 Nm).
  6. Raise and support the front of the vehicle safely on jackstands.
  7. Tighten the 2 lower mounting bolts to 15-20 ft. lbs. (20-30 Nm).
  8. Lower the vehicle.
  9. Install the other power steering pressure hose to the steering gear, then tighten to 13-17 ft. lbs. (17-23 Nm).
  10. Connect the power steering reservoir pump hose to the power steering pump.
  11. Fill and bleed the hydraulic power steering system.

BLEEDING

  1. Fill the power steering pump reservoir.
  2. Raise the front wheel and tire assemblies off the ground and support the vehicle with jack stands.
  3. Disable the ignition system.
  4. Turn the steering wheel lock to lock while cranking the engine. While cranking, add power steering fluid until the level in the reservoir stays constant.

Do not hold the steering against the lock for more than 5 seconds at a time or damage to the power steering pump may result.

  1. Check the fluid level and add if necessary.
  2. Restore the ignition system.
  3. Start the engine and allow it to idle for several minutes.
  4. Remove the jack stands.
  5. Lower the vehicle.
  6. Rotate the steering wheel from lock to lock several times.
  7. Turn the engine OFF and check the fluid level again.
  8. Road test the vehicle and check for proper power steering system operation.

Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning.