FORD: 2001-2003 Explorer Sport
2001-2005 Explorer Sport Trac
This article supersedes TSB 04-2-7 to update the vehicle model years and service procedure.
ISSUE:
Some 2001-2005 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction between the tire and the road surface, which is amplified through the steering system. The condition will vary according to ambient temperature, road surface friction, and steering wheel turning speed.
ACTION:
As design changes have taken place in the steering system, it is important to note the VEHICLE BUILD DATE and follow the appropriate steps outlined in the following Service Procedure. Perform a thorough evacuation of air from the power steering system after replacement/installation of parts.
SERVICE PROCEDURE
NOTE: BEFORE REPLACING ANY COMPONENT, BE SURE TO CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE.
NOTE: THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED OF AIR WITH A VACUUM AT THE RESERVOIR. FILL AND PURGE THE P/S SYSTEM FOLLOWING THE PROCEDURES CALLED OUT IN THE ON-LINE WORKSHOP MANUAL, SECTION 211-00. FOLLOWING THE EVACUATION PROCEDURE WILL REDUCE THE AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER.
NOTE: PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED.
VEHICLES BUILT PRIOR TO APRIL 18, 2001
Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer to Workshop Manual, Section 211-02.
Replace the cooler assembly with service part F77Z-3D746-GA. Do not remove the existing cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the new return line from the new cooler and connect the new cooler fin pack to the existing return line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for complete replacement instructions.
Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE O-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE O-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
Replace the check valve located in the steering gear pressure side inlet port with a no-hole check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figures 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear.
Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section 211-00.
Reprogram the powertrain control module (PCM) to the latest calibration using WDS release B28.5 or higher. Calibration files may also be obtained at www.motorcraft.com.
