1993 Bronco/Econoline/F-Series

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Page 1 of 7 Section 11-02A: Steering Pump, Power, C-II DISASSEMBLY AND ASSEMBLY Workshop Manual Power Steering Pump NOTE: Prior to disassembly of the power steering pump, the pump must be removed

1 Page 1 of 7 Section 11-02A: Steering Pump, Power, C-II DISASSEMBLY AND ASSEMBLY Workshop Manual Power Steering Pump NOTE: Prior to disassembly of the power steering pump, the pump must be removed from the vehicle. Refer to removal and installation procedures in this section. The following precautions must be observed when servicing the power steering pump: 1. Use a clean workbench and tools. 2. Thoroughly clean the exterior of the pump with solvent. Drain as much fluid as possible. 3. Do not use cleaning solvent on the seals. Disassembly 1. Remove the outlet fitting, flow control valve, and spring from the pump. Remove the pump reservoir by lifting the pump housing. 2. Place C-clamp T74P-3044-A1 in a bench vise. 3. Place the lower support plate T78P-3733-A2 over the pump rotor shaft. 4. Install the upper compressor plate tool T78P-3733-A1 into the upper portion of the C-clamp. 5. While holding the upper compressor tool, place the pump assembly into the C-clamp with the rotor shaft facing down. NOTE: Position the contour of the upper compressor tool to fit the contour of the pump valve cover. 6. Tighten C-clamp until a slight bottoming of the valve cover is felt. 7. In the side of the pump housing plate is a small hole. Insert a small drift or suitable tool through this hole and push inward on the valve cover retaining ring. While applying pressure on the retaining ring, place a screwdriver under the edge of the retaining ring and remove the ring.

2 Page 2 of 7 8. Loosen C-clamp. Remove the upper compressor plate, and remove the pump assembly. 9. Remove the pump valve cover. Discard the O-ring seal. 10. Push on the rotor shaft, and remove the rotor shaft, upper plate, rotor and slippers, cam insert and two dowel pins. 11. The lower plate and the disc spring will remain in the pump housing plate. To remove, place the pump housing plate on a flat surface. Raise slightly and slam the housing plate down until the lower plate and the disc spring fall out. Discard the O-ring seals. 12. Remove the rotor shaft seal and seal retainer simultaneously by prying out with a screwdriver. NOTE: This method is used only when the pump is disassembled. Assembly

3 Page 3 of 7 If the rotors, slippers, spring and cam insert were disassembled for cleaning and/or inspection, assemble as follows: 1. Place the rotor on the rotor shaft splines. 2. Install the retaining ring in the groove at the end of the rotor shaft using Retaining Ring Pliers D79L-7000-A or equivalent. 3. Place the insert cam over the rotor. Be sure the recessed flat on the insert cam is toward the reservoir. 4. With the rotor extended upward approximately half-way out of the cam, insert a spring into a rotor spring pocket. 5. Use one of the slippers to compress the spring and install the slipper with the narrow groove facing upward. NOTE: The slippers must be oriented with the narrow rail spacing toward the cam, otherwise the pump will not function. 6. Hold the cam stationary, and turn the rotor either right or left one space at a time. Install another spring and slipper until all ten rotor cavities have been filled. Be careful when turning the rotor, that the springs and slippers already installed do not fall out. 7. Install a new rotor shaft seal using Seal Driver T78P-3733-A3. Using a plastic mallet, drive the seal into the bore until a bottoming is felt. Install the seal retainer in the same manner. 8. Place the pump housing plate on a flat surface, with the pulley side facing down. 9. Insert the two dowel pins and the disc spring into the housing plate. NOTE: The disc spring must be inserted with the dished surface upward.

Page 4 of 7 10. Lubricate the inner and outer O-ring seals with the specified power steering fluid and install these seals on the lower pressure plate. 11.

4 Page 4 of Lubricate the inner and outer O-ring seals with the specified power steering fluid and install these seals on the lower pressure plate. 11. Insert the lower pressure plate with the O-ring seals toward the front of the pump into the pump housing plate and over the dowel pins. 12. Place the entire assembly on the C-clamp. 13. Place driver T78P-3733-A3 into the rotor shaft hole and press on the lower plate lightly until it is felt to bottom into the pump plate housing. This operation will seat the outer O-ring seal.

Page 5 of 7 14. Install the cam, rotor and slippers, and rotor shaft assembly into the pump housing plate over the dowel pins.

approximately 180 degrees opposite the square pump mounting boss. 15. Place the upper pressure plate over the dowel pins.

5 Page 5 of Install the cam, rotor and slippers, and rotor shaft assembly into the pump housing plate over the dowel pins. NOTE: When installing this assembly into the pump housing plate, the stepped holes must be used for the dowel pins, and the recessed notch in the cam insert must face toward the reservoir and be approximately 180 degrees opposite the square pump mounting boss. 15. Place the upper pressure plate over the dowel pins. NOTE: When installing the upper plate into the pump housing, observe the notch on the outside diameter of the plate. One side has a square recess cast into the plate. This square recess must be facing toward the reservoir and positioned approximately 180 degrees opposite the pump square mounting boss. 16. Place a new O-ring seal on the valve cover. Lubricate this seal with specified power steering fluid. NOTE: Be sure the plastic baffle is securely in place in the valve cover. If the baffle is loose, apply a coating of petroleum jelly on the baffle and install

Place the entire assembly in the C-clamp T74P-3044-A1 and compress the valve cover into the pump housing plate, until the retaining ring groove is exposed in the pump housing plate. 19.

6 Page 6 of 7 it into location on the valve cover. 17. Insert valve cover over the dowel pins. Be sure the outlet fitting hole in the valve cover is directly in line with the square mounting boss of the pump housing plate. 18. Place the entire assembly in the C-clamp T74P-3044-A1 and compress the valve cover into the pump housing plate, until the retaining ring groove is exposed in the pump housing plate. 19. Install the valve cover retaining ring with the ends near the access hole in the pump housing plate. 20. Remove the pump assembly from the C-clamp tool. 21. Place a new O-ring seal on the pump housing plate. Lubricate O-ring seal with the specified power steering fluid. 22. Install the power steering reservoir. 23. Install the flow control spring and flow control valve into the valve cover. 24. Place new O-ring seals on the outlet fitting. Lubricate these seals with the specified power steering fluid. 25. Install the outlet fitting into the valve cover and tighten to Nm (25-40 ft-lb). Installing Outlet Fitting

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POWER STEERING PUMP REBUILDING SPK101 Read instructions completely before removal & disassembly

POWER STEERING PUMP REBUILDING SPK101 Read instructions completely before removal & disassembly DISASSEMBLY: 1. Remove pump from car and allow to drain. 2. Remove pulley from front of pump. This requires