1999 FORD RANGER Service Repair Manual

2008 STEERING
Power Steering - Ranger
SPECIFICATIONS
MATERIAL SPECIFICATIONS
a Capacities listed are average system capacities and may vary.
TORQUE SPECIFICATIONS
DESCRIPTION & OPERATION
POWER STEERING
The power steering system consists of the following components:
 Power steering pump
 Power steering fluid reservoir
 Power steering pressure and return lines/hoses
Item Specification Fill Capacity
MERCON® V Automatic
Transmission Fluid
XT-5-QM (or XT-5-QMC) (US);
CXT-5-LM12 (Canada)
MERCON® V 1L (2.1 pt)a
Premium Long-Life Grease
XG-1-C or XG-1-K (US); CXG-1-
C (Canada)
ESA-M1C75-B -
Description Nm lb-ft
Inner tie rod 100 74
Lower steering column shaft-to-steering gear bolt 55 41
Outer tie-rod end nut 80 59
Power steering fluid cooler nuts 40 30
Power steering fluid reservoir bolts 14 10
Power steering fluid reservoir nut (3.0L) 14 10
Pressure line-to-pump fitting 65 48
Power steering pump bolts (2.3L) 23 17
Power steering pump bolts (3.0L and 4.0L) 25 18
Power steering pump pulley bolts (3.0L and 4.0L) 25 18
Steering gear nuts 150 111
Steering line clamp plate nut 35 26
Tie-rod jam nut 80 59
2008 Ford Ranger
2008 STEERING Power Steering - Ranger
2008 Ford Ranger
Microsoft
Wednesday, November 11, 2009 11:21:15 AM Page 1 © 2005 Mitchell Repair Information Company, LLC.
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 Power steering fluid cooler
 Power steering gear
 Inner tie rod
The power steering system uses a vane-type pump to move the fluid from the reservoir to the steering gear and
through the rest of the steering hydraulic system. The power steering pump is mounted to the engine and driven
by the engine accessory drive belt. Power steering fluid flows into the pump from the reservoir. The power
steering fluid is then trapped between the pump vanes and moved to the high-pressure side of the pump creating
a flow of fluid. The restriction of this flow by the steering gear creates the pressure that provides the steering
assist. A combined pressure relief/flow valve is built into the pump to control the maximum pressure and flow
provided to the steering system. This action prevents damage to the system and provides the correct level of
assist during all engine speeds. While under pressure, the power steering fluid flows through the high-pressure
power steering line to the steering gear. The fluid exits the gear and flows through the return line, cooler and
finally to the reservoir. The reservoir slows the fluid, allows air to escape and filters the fluid before returning it
to the pump.
DIAGNOSTIC TESTS
POWER STEERING
Refer to STEERING SYSTEM - GENERAL INFORMATION article.
REMOVAL & INSTALLATION
POWER STEERING FLUID RESERVOIR - 2.3L & 4.0L
Material
Item Specification
MERCON® V Automatic Transmission Fluid
XT-5-QM (or XT-5-QMC) (US); CXT-5-LM12
(Canada)
MERCON® V
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Fig. 1: Identifying Power Steering Fluid Reservoir - 2.3L With Torque Specifications
Courtesy of FORD MOTOR CO.
Item Part Number Description
1 W503924
Power steering fluid reservoir bolts (3
required)
2 3R700 Power steering fluid reservoir
3 3A713 Return hose
4 3659 Power steering pump supply hose
2008 Ford Ranger
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Fig. 2: Exploded View Of Power Steering Fluid Reservoir - 4.0L Engine With Torque Specifications
2 3A005 Return hose
3 N606678
required)
CAUTION: While repairing the power steering system, care should be taken to
prevent the entry of foreign material or failure of the power steering
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All vehicles
1. Using a suitable suction device, remove the power steering fluid from the reservoir.
2. Compress the clamp and disconnect the return hose.
3. Compress the clamp and disconnect the power steering pump supply hose.
2.3L engines
4. Remove the 3 bolts and the power steering fluid reservoir.
 To install, tighten to 14 Nm (10 lb-ft).
4.0L engines
All vehicles
6. To install, reverse the removal procedure.
7. Fill the power steering system. For additional information, refer to STEERING SYSTEM - GENERAL
INFORMATION article.
POWER STEERING FLUID RESERVOIR - 3.0L
Material
components may result.
CAUTION: Do not allow power steering fluid to contact the engine accessory
drive belt or the belt may be damaged.
Item Specification
(Canada)
MERCON® V
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Fig. 3: Exploded View Of Power Steering Fluid Reservoir - 3.0L Engine With Torque Specifications
1 W503923
required)
2 W520101 Power steering fluid reservoir nut
4 CS7617 Power steering pump supply hose
5 3F731 Return hose
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2. Compress the clamp and disconnect the return hose.
4. Remove the power steering fluid reservoir nut.
POWER STEERING PUMP - 2.3L
Special Tools
Material
Illustration Tool Name Tool Number
Installer Set, Teflon® Seal
211-D027 (D90P-3517-A) or
equivalent
Item Specification
(Canada)
MERCON® V
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Fig. 4: Identifying Power Steering Pump - 2.3L With Torque Specifications
2. Remove the power steering pump pulley. For additional information, refer to Power Steering Pump
Pulley - 2.3L.
1 3A719 Pressure line-to-pump fitting
2 W705952 Power steering pump bolt (4 required)
3 C56697 Power steering pump supply hose
4 3A674 Power steering pump
5 N803257 Teflon® seal
CAUTION: Do not allow power steering fluid to contact the accessory drive belt
or the belt may be damaged.
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4. Disconnect the pressure line-to-pump fitting.
 Remove and discard the Teflon® seal.
5. Remove the 4 power steering pump bolts and the power steering pump.
 Using the special tool, install a new Teflon® seal on the pressure line-to-pump fitting.
 Fill the power steering system. For additional information, refer to STEERING SYSTEM -
GENERAL INFORMATION article.
Fig. 5: Installing Teflon(R) Seal Using Special Tool
Special Tools
Material
CAUTION: A new Teflon® seal must be installed any time the pressure line
fitting is disconnected from the power steering pump or a fluid leak
may occur.
211-D027 (D90P-3517-A) or
equivalent
Item Specification
(Canada)
MERCON® V
2008 Ford Ranger
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Fig. 6: Exploded View Of Power Steering Pump - 3.0L Engine With Torque Specifications
Pulley - 3.0L, 4.0L.
1 N605784 Power steering pump bolt (3 required)
3 CS7617 Power steering pump supply hose
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 Remove and discard the Teflon® seal.
5. Remove the 3 bolts and the power steering pump.
Special Tools
Material
CAUTION: A new Teflon® seal must be installed any time the pressure line
fitting is disconnected from the power steering pump or a fluid leak
may occur.
211-D027 (D90P-3517-A) or
equivalent
Item Specification
(Canada)
MERCON® V
2008 Ford Ranger
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Fig. 8: Exploded View Of Power Steering Pump - 4.0L With Torque Specifications
2. Remove the engine cooling fan. For additional information, refer to ENGINE COOLING article.
Pulley - 3.0L, 4.0L.
3 W700839 Power steering pump bolt (3 required)
CAUTION: Do not allow power steering fluid to contact the accessory drive belt
or the belt may be damaged.
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4. Compress the clamp and disconnect the power steering pump supply hose from the power steering fluid
reservoir.
6. Compress the clamp and disconnect the power steering pump supply hose from the power steering pump.
7. Remove the 3 bolts and the power steering pump.
 Tighten to 25 Nm (18 lb-ft).
8. To install, reverse removal procedure.
POWER STEERING PUMP PULLEY - 2.3L
Special Tools
CAUTION: A new Teflon® seal must be installed any time the pressure line is
disconnected from the power steering pump or a fluid leak may
occur.
Remover, Power Steering Pump
Pulley
211-016 (T69L-10300-B)
Installer, Power Steering Pump
Pulley
211-185 (T91P-3A733-A)
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Fig. 10: Identifying Power Steering Pump Pulley - 2.3L
REMOVAL
1. Remove the air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION
& FILTERING article.
2. Rotate the accessory drive belt tensioner counterclockwise and position the accessory drive belt aside.
1 3D673 Power steering pump pulley
2 8620 Accessory drive belt
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Fig. 11: Locating Accessory Drive Belt Tensioner
3. Using the special tool, remove the power steering pump pulley.
Fig. 12: Removing Pulley Using Special Tool (211-016)
INSTALLATION
1. Using the special tool, install the power steering pump pulley.
CAUTION: Do not install a power steering pump pulley that has been removed
and installed twice or pulley failure and/or pump damage may occur.
Inspect the pulley for paint marks in the web area near the hub. If
there are 2 paint marks, discard the pulley and install a new one. If
there is 1 paint mark or no paint marks, use a paint pencil to mark the
web area of the pulley near the hub.
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Fig. 13: Installing Pulley Using Special Tool (211-185)
2. Rotate the tensioner counterclockwise and position the belt on the power steering pump pulley.
Fig. 14: Locating Accessory Drive Belt Tensioner
3. Install the air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION &
FILTERING article.
POWER STEERING PUMP PULLEY - 3.0L, 4.0L
NOTE: For additional information on accessory drive belt routing, refer to
ACCESSORY DRIVE article.
2008 Ford Ranger
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Fig. 15: Identifying Power Steering Pump Pulley - 3.0L, 4.0L With Torque Specifications
1. Loosen the power steering pump pulley bolts.
2. Rotate the accessory drive belt tensioner counterclockwise and position the accessory drive belt aside.
3. Remove the 3 bolts and the power steering pump pulley.
INNER TIE ROD
1 N605784
Power steering pump pulley bolts (3
required)
2 3A733 Power steering pump pulley
3 8620 Accessory drive belt
NOTE: 4.0L engine shown in illustration, 3.0L engine similar.
NOTE: For additional information on accessory drive belt routing, refer to
ACCESSORY DRIVE article.
2008 Ford Ranger
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Special Tools
Material
Fig. 16: Identifying Inner Tie Rod With Torque Specifications
Inner Tie-Rod Socket Tool 211-D029 or equivalent
Tie-Rod End Separator
211-105 (T85M-3395-A) or
equivalent
Item Specification
Premium Long-Life Grease
XG-1-C or XG-1-K (US); CXG-1-C (Canada)
ESA-M1C75-B
1 N803637
Tie-rod jam nut (part of 3280) (2
required)
2008 Ford Ranger
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Coil spring suspension vehicles
1. Remove the wheel and tire. For additional information, refer to WHEELS & TIRES article.
2. Loosen the tie-rod jam nuts.
3. Remove the outer tie-rod end cotter pin and nut.
 Discard the cotter pin.
4. Using the special tool, disconnect the outer tie-rod end.
2 N800895 Outer tie-rod end nut (2 required)
3 3290 Outer tie-rod end (2 required)
4 3K745 Outer bellows boot clamp (2 required)
5 3C650A Inner bellows boot clamp (2 required)
6 3K661 Steering gear bellows boot (2 required)
7 3280 Inner tie rod (2 required)
8 N642569 Cotter pin (2 required)
CAUTION: The boots and clamps are designed to provide an airtight seal and protect
the internal components of the steering gear. If the seal is not airtight, the
vacuum generated during turning may draw water and foreign material
into the gear and damage internal components. Zip ties do not produce an
airtight seal and must not be used.
CAUTION: The inner ball joint grease is not compatible with water. Water and foreign
material trapped in the grease may damage the joint.
CAUTION: If present, the orientation of the vent tubes must be noted so the boots
and vent tubes may be installed in their original locations. Incorrect
venting may lead to internal component damage.
CAUTION: Do not damage the tie-rod end boot when installing the special tool.
2008 Ford Ranger
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Fig. 17: Identifying Special Tool On Tie-Rod End
5. Remove the outer tie-rod end.
6. Remove the tie-rod jam nut.
7. Remove the inner and outer bellows boot clamps.
8. Remove the bellows boot.
9. Using the special tool, remove the inner tie rod.
NOTE: Count and record the number of times the outer tie-rod end turns for
assembly reference.
NOTE: If repairing the RH side, it will be necessary to pull back the LH inner
bellows boot to hold the steering gear.
CAUTION: Place the steering gear at the center position. Use a 21 mm (0.82 in)
crowfoot on the flat of the rack gear to resist rotation and to prevent
damage during removal and installation of the inner tie rod.
NOTE: The help of an assistant may be needed for removal of the RH inner tie
rod.
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Fig. 18: Inner Tie Rod And Special Tool
Torsion bar suspension vehicles
10. Loosen the tie-rod jam nut.
11. Remove the steering gear. For additional information, refer to Steering Gear - Rear Wheel Drive
(RWD) or Steering Gear - Four Wheel Drive (4WD).
12. Remove the outer tie-rod end and jam nut.
13. Remove the inner and outer bellows boot clamps.
14. Using the special tool, remove the inner tie rod.
Fig. 19: Locating Inner Tie Rod
All vehicles
NOTE: Count and record the number of times the outer tie-rod end turns for
assembly reference.
NOTE: If repairing the RH side, it will be necessary to pull back the LH inner
bellows boot to hold the steering gear.
CAUTION: Place the steering gear at the center position. Use a 21 mm (0.82 in)
crowfoot on the flat of the rack gear to resist rotation and to prevent
damage during removal and installation of the inner tie rod.
NOTE: The help of an assistant may be needed for removal of the RH inner tie
rod.
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15. Thoroughly clean and inspect all the parts to be reused. Install new parts as necessary.
16. Check that the bellows boot seal is positioned correctly over the steering gear housing bead at the large
inside diameter (ID) and is in the inner tie-rod groove at the small ID.
 Check that the bellows boot seal is not twisted and the breather tube is securely inserted into the
breather nipple at both bellows boots.
18. Check and if necessary adjust the front toe. For additional information, refer to SUSPENSION SYSTEM
- GENERAL INFORMATION article.
POWER STEERING FLUID COOLER
Material
CAUTION: Thoroughly remove any dirt or foreign material that is present. This
material is extremely harmful to the steering gear.
NOTE: Lubricate the inner tie rod inside groove with steering gear grease where
the bellows boot is clamped.
Item Specification
(Canada)
MERCON® V
2008 Ford Ranger
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Fig. 20: Identifying Power Steering Fluid Cooler With Torque Specifications
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING &
LIFTING article.
2. Remove the 2 power steering fluid cooler nuts.
3. Compress the clamps and disconnect the 2 power steering fluid cooler hoses.
STEERING GEAR - REAR WHEEL DRIVE (RWD)
Special Tools
1 3A713B Power steering fluid cooler hose
2 3A713A Power steering fluid cooler hose
3 N800169
Power steering fluid cooler nuts (2
required)
4 3F780 Power steering fluid cooler
Remover, Tie-Rod End
211-001 (TOOL-3290-D) or
equivalent
2008 Ford Ranger
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Fig. 21: Identifying Steering Gear - Rear Wheel Drive (RWD) With Torque Specifications
1 W520413 Steering line clamp plate nut
2 3A713 Return line
3 3A719 Pressure line
4 N803256 O-ring seal
6 N811762 Steering gear studs (2 required)
7 N803942
Lower steering column shaft-to-steering
gear bolt
8 3504 Steering gear
9 N808265 Steering gear nuts (2 required)
2008 Ford Ranger
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All vehicles
1. Remove the front wheels and tires. For additional information, refer to WHEELS & TIRES article.
2. Place the steering wheel in the straight-ahead position and remove the ignition key.
 Rotate the steering wheel until the steering column locks into position.
3.0L and 4.0L engines
3. Remove the power steering fluid cooler. For additional information, refer to Power Steering Fluid
Cooler.
All vehicles
4. Remove the outer tie-rod end cotter pins and nuts.
 Discard the cotter pins.
5. Using special tool, separate the outer tie-rod ends from the wheel spindles.
CAUTION: When repairing the power steering system, care should be taken to
CAUTION: Do not damage the tie-rod boot when installing the special tool.
NOTE: Remove the adapter from the ball end of the special tool. Apply a small
amount of grease to the tie-rod end stud and the ball of the special tool.
2008 Ford Ranger
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Fig. 22: Separating Outer Tie Rods From Wheel Knuckles
6. Remove the lower steering column shaft-to-steering gear bolt and disconnect the lower steering column
shaft from the gear.
 Discard the bolt.
7. Remove the steering line clamp plate nut and disconnect the pressure and return lines.
 Discard the O-ring seals.
8. Plug or cap the return line, pressure line and the steering gear ports to prevent the entry of dirt.
9. Remove the 2 steering gear nuts and the 2 steering gear studs.
10. Remove the steering gear.
11. If necessary, remove the outer tie-rod ends.
 Install new power steering line O-ring seals.
14. Check and, if necessary, adjust the front toe.
STEERING GEAR - FOUR WHEEL DRIVE (4WD)
Special Tools
CAUTION: Do not allow the steering column to rotate while the steering column
shaft is disconnected from the steering gear or damage to the
clockspring may result. If there is evidence that the steering column
has rotated, the clockspring must be removed and recentered. For
additional information, refer to SUPPLEMENTAL RESTRAINT
SYSTEM article.
CAUTION: Hold the tops of the steering gear studs to avoid damaging the
steering gear fluid transfer tubes.
CAUTION: New O-ring seals must be installed any time the power steering lines
are disconnected from the steering gear or a fluid leak may occur.
2008 Ford Ranger
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Fig. 23: Identifying Steering Gear - Four Wheel Drive (4WD) With Torque Specifications
Remover, Tie-Rod End
211-001 (TOOL-3290-D) or
equivalent
1 W520413 Steering line clamp plate nut
2 3A713 Return line
3 3A719 Pressure line
2008 Ford Ranger
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REMOVAL
All vehicles
1. Remove the front wheels and tires. For additional information, refer to WHEELS & TIRES article.
2. Place the steering wheel in the straight-ahead position and remove the ignition key.
 Rotate the steering wheel until the steering column locks into position.
3. Remove the power steering fluid cooler. For additional information, refer to Power Steering Fluid
Cooler.
All vehicles
4. Loosen the tie-rod jam nuts.
5. Remove the outer tie-rod end cotter pins and nuts.
 Discard the cotter pins.
6. Using the special tool, separate the outer tie-rod ends from the wheel knuckles.
6 N811762 Steering gear studs (2 required)
7 N803942
Lower steering column shaft-to-steering
gear bolt
8 3504 Steering gear
9 N803637
Tie rod jam nut (part of 3280) (2
required)
10 N808265 Steering gear nuts (2 required)
11 3290 Outer tie-rod end (2 required)
CAUTION: When repairing the power steering system, care should be taken to
CAUTION: Do not damage the tie-rod boot when installing the special tool.
NOTE: Remove the adapter from the ball end of the special tool. Apply a small
amount of grease to the tie-rod end stud and the ball of the special tool.
2008 Ford Ranger
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Fig. 24: Separating Outer Tie Rods From Wheel Knuckles
7. Remove the outer tie-rod ends.
 Count and record the number of turns required to remove the outer tie-rod end.
8. Remove the stabilizer bar and link. For additional information, refer to FRONT SUSPENSION - FOUR
WHEEL DRIVE (4WD) article.
9. Remove the lower steering column shaft-to-steering gear bolt and disconnect the shaft from the steering
gear.
 Discard the bolt.
10. Remove the steering line clamp plate nut and disconnect the pressure and return lines.
 Discard the O-ring seals.
11. Remove the 2 steering gear nuts and steering gear studs.
12. Rotate the steering gear control valve housing toward the front of the vehicle.
has rotated, the clockspring must be removed and recentered. For
SYSTEM article.
2008 Ford Ranger
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Fig. 25: Rotating Steering Gear Control Valve Housing Toward Front Of Vehicle
13. Turn the steering gear input shaft to the right until the stop is reached.
14. Move the steering gear as far to the RH side of the vehicle as possible.
Fig. 26: Moving Steering Gear As Far To RH Side Of Vehicle As Possible
15. Move the LH inner tie rod forward to clear the frame crossmember.
Fig. 27: Locating LH Inner Tie Rod
16. Remove the steering gear.
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Fig. 28: Removing Steering Gear
INSTALLATION
All vehicles
1. Turn the steering gear input shaft to the right until the stop is reached. Count and record the number of
turns required.
2. Install the steering gear into the RH opening of the crossmember.
Fig. 29: Installing Steering Gear Into RH Opening Of Crossmember
CAUTION: Handle the steering gear with caution to avoid damage to fluid
transfer tubes and to avoid dimples in the steering gear bellows boot.
NOTE: Make sure the steering gear input shaft is turned to the left until the stop is
reached.
NOTE: Make sure the steering gear control valve housing is turned toward the
front of the vehicle.
CAUTION: Take care not to scuff or tear the steering gear bellows boots.
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3. Move the steering gear as far to the RH side of the vehicle as possible.
Fig. 30: Moving Steering Gear As Far To RH Side Of Vehicle As Possible
4. Move the LH inner tie rod into the opening in the crossmember and move the steering gear into position.
Fig. 31: Locating LH Inner Tie Rod
5. To place the steering gear in the straight-ahead position, turn the steering gear input shaft to the left by
1/2 the number of turns previously recorded.
6. Rotate the steering gear control valve housing toward the rear of the vehicle.
Fig. 32: Rotating Steering Gear Control Valve Housing Toward Rear Of Vehicle
7. Install the 2 steering gear studs.
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8. Install the 2 steering gear nuts.
9. Position the pressure and return lines and install the steering line clamp plate nut.
10. Connect the steering column shaft to the steering gear and install a new bolt.
11. Install the stabilizer bar and link. For additional information, refer to FRONT SUSPENSION - FOUR
WHEEL DRIVE (4WD) article.
12. Install the outer tie-rod ends.
 Rotate the outer tie-rod ends the number of turns recorded during removal.
13. Position the outer tie-rod ends and install the nuts and new cotter pins.
 Check that the brake disc shields are not bent and are not in contact with the outer tie-rod end
boots.
14. Install the power steering fluid cooler. For additional information, refer to Power Steering Fluid Cooler.
All vehicles
15. Tighten the tie-rod jam nuts.
17. Check and, if necessary, adjust the front toe. For additional information, refer to SUSPENSION
SYSTEM - GENERAL INFORMATION article.
CAUTION: New O-rings must be installed any time the lines are disconnected
from the steering gear or a fluid leak may occur.
has rotated, the clockspring must be removed and re-centered. For
SYSTEM article.
2008 Ford Ranger
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1999 FORD RANGER Service Repair Manual

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