1999 steering problem...

Howdy!

Newbie to forum - y'all look like a friendly bunch!!

Horrendus noise coming from wife's 1999 Windstar, 3.8 L, ~111 k miles. Only made noise when turning. Initially thought it was steering pump. Called up local parts shops only to find out all of them had to special order the part. Only the Ford dealer had it in stock and at the extra $110 price over Autozone, I figured I'd wait the extra 2 days and get the $70 reman there. Rather straightforward installation only to find out that wasn't the problem, DOH!! Turns out the left side sway bar link was shot on the lower end!! I just replaced both tie rod ends and both links in March!! Oh well back to Advance auto Parts (Hey, ya gotta' spread the wealth) for replacement (lifetime - yippee!!). Put new in and all is quiet - YAY! BUT, now I have no power steering!!! Went back and did a full flush of the system with Mercon - about 2 quarts total - as per spec (man was that old stuff black and nasty smelling, just as was noted in previous posts). Rebled the system. Test drive (what a bear). Let engine / fluids cool. Retopped level. NO JOY!! When engine is running I can see fluid returning to PS resevoir. Idle per tach is about 750 (always has been). As soon as rpms get to about 900 or so all is well with PS. On deceleration as in coming off Interstate or at local corner can't get ps to work until you give it gas - really bad if somebody elses car is already at the intersection you're going to make a right turn at.
Does anybody have any clues as to what the problem is? Vehicle has never had PS issues in past. Hunted through forum but couldn't see anything like this - althought my kids say I'm blind - so it wouldn't surprise me to miss something.
Any clues will be much appreciated, thanks!!
Terry

Howdy!

Newbie to forum - y'all look like a friendly bunch!!

Horrendus noise coming from wife's 1999 Windstar, 3.8 L, ~111 k miles. Only made noise when turning. Initially thought it was steering pump. Called up local parts shops only to find out all of them had to special order the part. Only the Ford dealer had it in stock and at the extra $110 price over Autozone, I figured I'd wait the extra 2 days and get the $70 reman there. Rather straightforward installation only to find out that wasn't the problem, DOH!! Turns out the left side sway bar link was shot on the lower end!! I just replaced both tie rod ends and both links in March!! Oh well back to Advance auto Parts (Hey, ya gotta' spread the wealth) for replacement (lifetime - yippee!!). Put new in and all is quiet - YAY! BUT, now I have no power steering!!! Went back and did a full flush of the system with Mercon - about 2 quarts total - as per spec (man was that old stuff black and nasty smelling, just as was noted in previous posts). Rebled the system. Test drive (what a bear). Let engine / fluids cool. Retopped level. NO JOY!! When engine is running I can see fluid returning to PS resevoir. Idle per tach is about 750 (always has been). As soon as rpms get to about 900 or so all is well with PS. On deceleration as in coming off Interstate or at local corner can't get ps to work until you give it gas - really bad if somebody elses car is already at the intersection you're going to make a right turn at.
Does anybody have any clues as to what the problem is? Vehicle has never had PS issues in past. Hunted through forum but couldn't see anything like this - althought my kids say I'm blind - so it wouldn't surprise me to miss something.
Any clues will be much appreciated, thanks!!
Terry

Terry

It sounds like you either have a blockage in the power stearing or your rack and pinion is leaking inside and requires the extra psi from the higher rpms to get power assist. You may have a replace your rack.

If you do replace your rack you'll want to flush the system and install an inline filter. You don't want any of that crud in the replacement rack.

Regards

Dan

Thanks (I think) Dan...

I don't think there's a blockage due to the fact there seems to be nice return flow to resevoir and there was nice flow when flushing system.

Anybody know any cheap and dirty way to check pressure in PS system without buying some unique gauge with this as it's only use?

Thanks

Terry

Sounds to me as though your PS problem actually began with the installation of the reman pump assembly. I would guess that it has an internal pressure relief valve that is the culprit.

I'd lean on AutoZone for yet another pump assembly .... Remember that lifetime warranty!

A power strg pump will last "forever" ... if it pumps only good clean fluid. But a few minutes running dry, or dirty, will waste it.

I suggest the following when installing a pump:

1. Install pump, but leave hi-press hose disconnected. Don't install belt ... yet. Fill reservoir with new fluid.

2. Turn pump pulley by hand, in correct direction, until pump is well primed. Connect outlet hose. Continue to turn by hand ... may require wrench.

3. Install belt. Overfill reservoir. Install cap loosely. Start engine and shut down after few seconds. Continue until you are sure the system is well purged of air.

Even using the above steps, it will take a couple of days driving to totally work out all the air bubbles ... and the pump may be noisy until this happens.

Thanks for the reply 12 ounce!

Got a new steering pump and that was the ticket, but now I'm getting drips - more like small puddles of steering fluid (atf) - from what seems to be the r/p boots. Could it be the system was used to the lower pressure in the old pump and now with the new pump, it has blown out the rack!! My wife is getting really annoyed at having to drive my E-150 van (aka the "Cream Cathedral") around. Any help out there would be appreciated. Also, any tips / hints / time estimate on rack replacement would be nice too!!

Tanx to all!!

Terry

There were a number of steering rack end-seal failures on the '99. Mine was replaced while vehicle was still under warranty.

I would contact dealer to see if there is still some "help" available from Ford on this known problem.

The Motorcraft power steering pump would have been a rebuilt also. I would suspect that your steering unit was working hard when the worn suspension parts were still on there.... Also, I wonder if there would have been an effect on the rack from your "manual" steering at low RPMs. Also, the seal failure is likely not related to the pump / suspension issues....and just simply wore out..... You may want to install a filter in the low pressure fluid line that goes from the cooler to the resevoir. You will need one that will fit 3/8" ID hose. I posted pics of my filter at http://community.webshots.com/album/201931518cScpNK The picture name is "power steering filter"
The filter that I installed, has a magnet inside to catch metal "sand", a paper filter element.....and a pressure bypass in case it gets clogged with crud. I installed the "deluxe" P/S filter that was listed for my car at www.rockauto.com The filter came with the hardware needed to install it. Easy (messy) install.

Question - does end-seal failure require entire rack replacement or am I just looking at seal replacement?
Thanks,
Terry

I guessing that the repair/rebuild of the steering rack requires so many special processes that (usually) it is outsourced to a shop set up for it. I doubt if parts are available for the DYI. ... but as I said; I'm guessing.

My rack was replaced ... not repaired. They are available on a repaired/exchange basis in many parts stores.

Replacing the rack is not a super-difficult job, but does require some skill level. The steering column is involved ... and front alignment is a necessary follow-up.