1991 1999 ford explorer chilton User Manual
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ADJUSTMENTS Measuring the steering gear preload Preload and Meshload INSPECTION Raise and support the front of the vehicle on jackstands. 1. Disconnect the pitman arm at the ball stud. 2. Lubricate the wormshaft seal with a drop of automatic transmission fluid. 3. Remove the horn pad from the steering wheel. 4. Turn the steering wheel slowly to one stop. 5. Using an inch-pound torque wrench on the steering wheel nut, check the amount of torque needed to rotate the steering wheel through a 1 1 /2 turn cycle. The preload should be 2-6 inch lbs. If correct, proceed with the rest of the steps. If not perform preload and mesh adjustment. 6. Rotate the steering wheel from stop-to-stop, counting the total number of turns. Using that figure, center the steering wheel ( 1 /2 the total turns). 7. Using the inch-pound torque wrench, rotate the steering wheel 90° to either side of center, noting the highest torque reading over center. The meshload should be 4-10 inch lbs., or at least 2 inch lbs. more than the preload figure. 8. ADJUSTMENT Remove the steering gear from the vehicle. 1. Torque the sector cover bolts on the gear to 32-40 ft. lbs. 2. Loosen the preload adjuster nut and tighten the worm bearing adjuster nut until all end-play has been removed. Lubricate the wormshaft seal with a few drops of automatic transmission fluid. 3. Using an 11 /16 in., 12-point socket and an inch lbs. torque wrench, carefully turn the wormshaft all the way to the right. 4. Turn the shaft back to the left and measure the torque over a 1 1 /2 turn cycle. This is the preload reading. 5. Tighten or loosen the adjuster nut to bring the preload into range (5-6 inch lbs.). 6. Hold the adjuster nut while torqueing the locknut to 166-187 ft. lbs. 7. HOW TO USE THIS BOOK ADJUSTMENTS 957
Rotate the wormshaft stop-to-stop counting the total number of turns and center the shaft ( 1 /2 the total turns). 8. Using the torque wrench and socket, measure the torque required to turn the shaft 90° to either side of center. 9. Turn the sector shaft adjusting screw as needed to bring the meshload torque within the 9-11 inch lbs. range, or at least 4 inch lbs. higher than the preload torque. 10. Hold the adjusting screw while tightening the locknut to 14-25 ft. lbs. 11. Install the gear. 12. REMOVAL & INSTALLATION View of the Ranger manual steering gear and related partsClick to enlarge Raise and safely support the vehicle using jackstands. Disengage the flex coupling shield from the steering gear input shaft shield and slide it up the intermediate shaft. 1. Remove the bolt that retains the flex coupling to the steering gear. 2. Remove the steering gear input shaft shield. 3. Remove the nut and washer that secures the pitman arm to the sector shaft. Remove the pitman arm using pitman arm puller tool, T64P-3590-F or equivalent. Do not hammer on the end of the puller as this can damage the steering gear. 4. Remove the bolts and washers that attach the steering gear to the side rail. Remove the gear. 5. To install: Rotate the gear input shaft (wormshaft) from stop to stop, counting the total number of turns. Then turn back exactly half-way, placing the gear on center. 6. Slide the steering gear input shaft shield on the steering gear input shaft. 7. Position the flex coupling on the steering gear input shaft. Ensure that the flat on the gear input shaft is facing straight up and aligns with the flat on the flex coupling. Install the steering gear to side rail with bolts and washers. Torque the bolts to 66 ft. lbs. (89 Nm). 8. HOW TO USE THIS BOOK 958 REMOVAL & INSTALLATION
Place the pitman arm on the sector shaft and install the attaching washer and nut. Align the 2 blocked teeth on the Pitman arm with 4 missing teeth on the steering gear sector shaft. Tighten the nut to 12-228 ft. lbs. (230-310 Nm). 9. Install the flex coupling to steering gear input shaft attaching bolt and tighten to 50-62 ft. lbs. (68-84 Nm). 10. Snap the flex coupling shield to the steering gear input shield. 11. Check the system to ensure equal turns from center to each lock position. 12. Power Steering Gear ADJUSTMENTS Meshload As required, raise and support the vehicle using jackstands. 1. Disconnect the pitman arm from the sector shaft using tool T64P-3590-F or equivalent. 2. Disconnect and cap the fluid return line at the reservoir return line pipe. 3. Place the end of the return line in a clean container and turn the steering wheel from stop to stop several times to discharge the fluid from the gear. Discard the used fluid. 4. Turn the steering gear 45° from the right stop. 5. Remove the steering wheel hub cover. Attach an inch lb. torque wrench to the steering wheel nut and determine the torque required to rotate the shaft slowly about 1 /8 turn from the 45° position toward center. 6. Turn the steering wheel back to center and determine the torque required to rotate the shaft back and forth across the center position. 7. Specification for vehicles under 5000 miles is 12-24 inch lbs. If the vehicle has over 5000 miles, reset the meshload measured while rocking the input shaft over center is less than 10 inch lbs. greater than torque 45° from the right stop. 8. If reset is required loosen the adjuster locknut and turn the sector shaft adjuster screw until the reading is the specified value greater than the torque at 45° from the stop. Hold the sector shaft screw in place and tighten the locknut. 9. REMOVAL & INSTALLATION HOW TO USE THIS BOOK Power Steering Gear 959
View of the power steering gear and related parts used on Ranger and 1991-94 Explorer Click to enlarge Disconnect the pressure and return lines from the steering gear. Plug the lines and the ports in the gear to prevent entry of dirt. 1. Remove the upper and lower steering gear shaft U-joint shield from the flex coupling. Remove the bolts that secure the flex coupling to the steering gear and to the column steering shaft assembly. 2. Raise the vehicle and remove the pitman arm attaching nut and washer. 3. Remove the pitman arm from the sector shaft using tool T64P-3590-F. Remove the tool from the pitman arm. Do not damage the seals. 4. Support the steering gear, and remove the steering gear attaching bolts. 5. Work the steering gear free of the flex coupling. Remove the steering gear from the vehicle. 6. To install: Install the lower U-joint shield onto the steering gear lugs. Slide the upper U-joint shield into place on the steering shaft assembly. 7. Slide the flex coupling into place on the steering shaft assembly. Turn the steering wheel so that the spokes are in the horizontal position. Center the steering gear input shaft. 8. Slide the steering gear input shaft into the flex coupling and into place on the frame side rail. Install the attaching bolts and tighten to 50-62 ft. lbs. (68-84 Nm). Tighten the flex coupling bolt 30-40 ft. lbs. (41-54 Nm). 9. Be sure the wheels are in the straight ahead position, then install the pitman arm on the sector shaft. Install the pitman arm attaching washer and nut. Tighten nut to 170-228 ft. lbs. (230-310 Nm). 10. Connect and tighten the pressure and the return lines to the steering gear. 11. Disconnect the coil wire. Fill the reservoir. Turn on the ignition and turn the steering wheel from left to right to distribute the fluid. 12. Recheck fluid level and add fluid, if necessary. Connect the coil wire, start the engine and turn the steering wheel from side to side. Inspect for fluid leaks. 13. HOW TO USE THIS BOOK 960 REMOVAL & INSTALLATION
Power Rack and Pinion Steering Gear REMOVAL & INSTALLATION WARNING If equipped, always turn off the Automatic Ride Control (ARC) service switch before lifting the vehicle off of the ground. Failure to do so could damage the ARC system components. Refer to Section 1 for jacking procedures. Raise and safely support the front of the vehicle, block the rear wheels and apply the parking brake. 1. Start the engine then rotate the steering wheel from lock-to-lock and record the number of rotations. 2. Divide the number of rotations by two. This gives the number of rotations to achieve true center of the steering. Turn the wheel in one direction to the full lock. 3. Turn the wheel in the opposite direction the number of turns equal to true steering (lock-to-lock number divided by two). 4. WARNING Do not rotate the steering wheel when the shaft is disconnected from the steering gear as damage to the clock spring could occur. Remove the bolt retaining the lower steering column shaft to the steering gear input shaft and disconnect the two. 5. Remove the stabilizer bar. 6. View of the power steering hose connections for the power rack and pinion steering gear Click to enlarge HOW TO USE THIS BOOK Power Rack and Pinion Steering Gear 961
Exploded view of the power rack and pinion steering gear mounting Click to enlarge Unscrew the quick-connect fittings for the power steering pressure and return hoses at the steering gear housing. 7. Plug the ends of the lines and the fitting in the rack to avoid dirt contamination. 8. Remove the two nuts securing the power steering cooler and remove the cooler. 9. Remove the outer tie rod ends. 10. Remove the two nuts, bolts and washer assemblies retaining the steering gear housing to the front crossmember. 11. To install: HOW TO USE THIS BOOK 962 REMOVAL & INSTALLATION
Position the steering gear to the front crossmember and install the nuts, bolts and washer assemblies. Tighten to 94-127 ft. lbs. (128-11 Nm). 12. Install the power steering cooler and two retaining bolts. 13. Connect the power steering lines to the steering gear housing and tighten the fittings to 20-25 ft. lbs. (27-34 Nm). 14. Install the outer tie rod ends. 15. Ensure that the steering shaft or gear input shaft has not been rotated, then connect the two. 16. Install the intermediate shaft-to-steering input shaft retaining (pinch) bolt and tighten to 30-42 ft. lbs. (41-56 Nm). 17. Lower the vehicle and refill the power steering pump reservoir. 18. Bleed the air from the power steering system. Follow the procedures in this Section. 19. Ensure that there are no leaks and the fluid is maintained at the proper level. 20. Have the alignment checked and adjusted by a professional repair shop. 21. Power SteeringPump REMOVAL & INSTALLATION Exploded view of the power steering pump used on the 2.9L engine Click to enlarge HOW TO USE THIS BOOK Power SteeringPump 963
Exploded view of the power steering pump used on the 3.0L engine Click to enlarge HOW TO USE THIS BOOK 964 REMOVAL & INSTALLATION
Exploded view of the power steering pump used on the 4.0L engine Click to enlarge Disconnect the negative battery cable. 1. Remove some power steering fluid from the reservoir by disconnecting the fluid return line hose at the reservoir. Drain the fluid into a container and discard it. 2. Remove the pressure hose from the pump. If equipped, disconnect the power steering pump pressure switch. 3. On the 2.3L, 2.5L and 3.0L engines, loosen the idler pulley assembly pivot and adjusting bolts to slacken the belt tension. 4. On the 2.9L engine loosen the adjusting nut and the slider bolts on the pump support to slacken belt tension. 5. On the 4.0L engine, slacken belt tension by lifting the tensioner pulley in a clockwise direction. Remove the drive belt from under the tensioner pulley and slowly lower the pulley to its stop. 6. Remove the drive belt from the pulley. If necessary, remove the oil dipstick tube. 7. If equipped, remove the power steering pump bracket support brace. 8. HOW TO USE THIS BOOK REMOVAL & INSTALLATION 965
Install power steering pump pulley removal tool T69L-10300-B or equivalent. Hold the pump and rotate the tool counterclockwise to remove the pulley. Do not apply in and out pressure to the pump shaft, as internal pump damage will occur. 9. Remove the power steering retaining bolts. Remove the power steering pump from the vehicle. 10. To install: Position the pump on the bracket. Install and tighten the retaining bolts. 11. Install the pulley removal tool and install the power steering pump pulley to the power steering pump. 12. Fore and aft location of the pulley on the power steering pump shaft is critical. Incorrect belt alignment may cause belt squeal or chirp. Be sure that the pull off groove on the pulley is facing front and flush with the end of the shaft ± 0.010 in. (0.25mm). Continue the installation in the reverse order of the removal procedure. Adjust the belt tension to specification. 13. On the 2.3L, 2.5L and 3.0L engines torque the idler pivot pulley bolts 30-40 ft. lbs. for the 2.3L, 2.5L engine and 35-47 ft. lbs. for the 3.0L engine 14. On the 2.9L engine torque the slider bolts to 35-47 ft. lbs. 15. On the 4.0L while lifting the tensioner pulley in a clockwise direction, slide the belt under the tensioner pulley and lower the pulley to the belt. 16. BLEEDING Disconnect the coil wire. 1. Crank the engine and continue adding fluid until the level stabilizes. 2. Continue to crank the engine and rotate the steering wheel about 30° to either side of center. 3. Check the fluid level and add as required. 4. Connect the coil wire and start the engine. Allow it to run for several minutes. 5. Rotate the steering wheel from stop to stop. 6. Shut of the engine and check the fluid level. Add fluid as necessary. 7. QUICK-CONNECT PRESSURE LINE Quick-disconnect coupling HOW TO USE THIS BOOK 966 BLEEDING