1996 Ford Windstar 3.8 Power Steering Pump Removal

The 1996 Ford 3.8-liter Windstar has a power steering pump with an integral fluid reservoir. Problems arise with the power steering pump from time to time, mostly because of the pressure relief valve or internal vane problems as opposed to leaks. The symptoms are an audible whining and in worst-case scenarios, the steering will suddenly and unpredictably have heavy resistance momentarily as the wheel is turned. This is more unsettling than dangerous. Replacing the steering pump is not difficult; it can be accomplished by a do-it-yourselfer and save money.

Instructions

Removal

1

Disconnect the negative battery cable using a wrench. Check for a belt routing diagram on the radiator support or the underside of the hood. If none exists, draw a picture of the belt routing to aid in installation.

2

Fit a socket onto the bolt in the center of the tensioner pulley for the serpentine belt. Rotate the tensioner toward the center of the engine to loosen tension on the belt. Lift the belt off the pulley.

3

Unplug the alternator wiring harness connector. Remove the battery positive cable from the back of the alternator using a socket or wrench. Put the nut back onto the terminal so you dont lose it. Remove the accessory drive belt tensioner by removing the bolt in the center of the tensioner; not the pulley, with a socket. Loosen the alternator pivot bolt with a socket. Remove the alternator brace using a socket. Remove the alternator pivot bolt and the alternator.

4

Fit the power steering pump pulley remover on the nose of the pulley, making sure the puller engages the groove in the nose. Hold the tools large nut with a wrench. Turn the center bolt clockwise with a wrench to remove the pulley. Slide the drain pan under the power steering pump. Disconnect the power steering pump pressure hose using a line wrench. Disconnect the return hose by loosening the clamp with a flat-head screwdriver. Allow the hoses to drain into the drain pan.

5

Remove the three power steering pump retaining bolts in the front and the power steering pump retaining bolt in the rear. Lift the pump and the support bracket out of the vehicle. Remove the pump from the support bracket using a socket.

Installation

6

Install the power steering pump onto the support. Torque the retaining bolts between the pump and support to 30 to 40 foot-pounds. Install the pump and support assembly onto the engine. Torque the retaining bolts to 30 to 40 foot-pounds.

7

Install the pressure line using a line wrench. Install the return line and tighten the clamp. Install the power steering pump pulley using the power steering pump pulley installer.

8

Reinstall the accessory drive belt tensioner. Reinstall the alternator, the pivot bolt and brace. Tighten the alternator brace to 15 to 22 foot-pounds of torque. Tighten the pivot bolt to 30 to 41 foot-pounds of torque. Plug in the alternator wiring harness. Reattach the battery positive terminal on the back of the alternator. Tighten the nut to 80 to 97 inch-pounds of torque.

9

Install the accessory drive belt, starting at the crankshaft pulley and routing it around the rest of the pulleys. Rotate the tensioner pulley toward the center of the engine and slide the belt onto the tensioner pulley. Release the pulley slowly, allowing it to put tension on the belt.

10

Reconnect the negative battery cable. Fill the power steering pump with power steering fluid to the Cold Fill line on the dipstick. Raise the front of the vehicle using the floor jack. Support it with jack stands. Start the engine. Turn the steering wheel from lock to lock until there is no longer signs of air in the power steering fluid. Do not place any pressure on the steering when it contacts the lock in either direction. Make sure the power steering fluid is not milky. Top off as necessary. Install the cap on the reservoir. Straighten the wheels and lower the vehicle. Drive the vehicle to test the power steering. Check the fluid again after returning from the test drive and top it off as necessary.