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Removal & Installation: Hose: Installation

  1. If new lines are to be installed, push lines into new unions. See Fig 1.
    Fig 1: Pushing Lines Into New Unions
    G00139278Courtesy of FORD MOTOR CO.
  2. Push a new O-ring onto a Teflon Seal Expander, 211-D027 (D90P-3517-A) or equivalent. Position the Teflon Seal Expander, 211-D027 (D90P-3517-A) or equivalent, onto the union and install the O-ring seal. See Fig 2.
    Fig 2: Installing New O-Ring Seals
    G00139279Courtesy of FORD MOTOR CO.
  3. Install power steering line unions to the steering gear see Figure and tighten to specification. See TORQUE SPECIFICATIONS .
  4. Install power steering return pressure line support bracket see Fig 3 and tighten to specification. See TORQUE SPECIFICATIONS .
    Fig 3: Installing Power Steering Return Pressure Line Support Bracket
    G00139281Courtesy of FORD MOTOR CO.
  5. Install power steering high-pressure line support bracket. See Figure.
  6. Push alignment pins through the subframe alining holes. Engage locking pins. Using Subframe Alignment Pins, 502-002 (T94P-2100-AH), tighten the alignment pin sleeves to align the front subframe assembly. See Fig 4.
    Fig 4: Aligning Front Subframe Assembly
    G00139282Courtesy of FORD MOTOR CO.
  7. Install front subframe assembly retaining bolts. See Figure.
  8. Loosen alignment pin sleeves. Disengage locking pins, and remove alignment pins from the subframe aligning holes. See Fig 4.
  9. Install the rear support insulator center bolt see Figure and tighten to specification. See TORQUE SPECIFICATIONS .
  10. Centralize the front support simulator and tighten nuts to specification. See TORQUE SPECIFICATIONS . Tighten the front simulator center bolt to specification. See TORQUE SPECIFICATIONS . See Figure.
    11. NOTE: Install a new gasket and nuts.
  11. Install catalytic converter to center muffler. See Figure. Tighten bolts to specification. See TORQUE SPECIFICATIONS .
  12. Attach the power steering fluid cooler lines retaining bracket see Figure. Tighten the fluid cooler lines to specification. See TORQUE SPECIFICATIONS .
  13. Attach bumper support brackets. See Figure. Tighten support bracket bolts to specification. See TORQUE SPECIFICATIONS .
  14. Lower vehicle.
  15. Install the power steering pump high-pressure line union. See Figure. Tighten union to specification. See TORQUE SPECIFICATIONS .
  16. Install the PSP switch and connect it with the switch electrical connector. See Figure.
    17. NOTE: Make sure the pulley is flush with the end of power steering pump shaft.
  17. Using a Power Steering Pump Pulley Installer 211-185 (T91P-3A733-A), install power steering pump pulley. See Figure.
  18. Install the coolant hose retaining bracket see Figure. Tighten the bracket bolt to specification.. See TORQUE SPECIFICATIONS .
  19. Install power steering high-pressure line support bracket. See Figure. Tighten the bracket bolt to specification. See TORQUE SPECIFICATIONS .
  20. Raise and support vehicle.
  21. Install accessory drive belt. For 1998-99 models, see SPECIFICATIONS & DRIVE BELT ROUTING - CARS article in ENGINE COOLING. For 2000 models, see SPECIFICATIONS - CARS article in ENGINE COOLING.
  22. Install lower splash shield. Rotate drive belt tensioner clockwise. See Figure.
  23. Install radiator splash shield. See Figure.
  24. Install the front road wheels. Tighten wheel nuts to specification. See TORQUE SPECIFICATIONS .
    25. CAUTION: Before lowering the vehicle make sure that the road wheels are in the straight ahead position.
  25. Lower the vehicle.
  26. Install accessory drive belt upper guard. See Figure. Tighten guard bolts to specification. See TORQUE SPECIFICATIONS .
    27. WARNING: Install a NEW pinch bolt. Failure to follow this instruction may result in personal injury.
  27. Install the steering column shaft flexible coupling. See Figure. Tighten the coupling bolt to specification. See TORQUE SPECIFICATIONS .
  28. Install floor seal. See Figure.
    29. WARNING: Install a new clamp bolt. Failure to follow this instruction may result in personal injury.
  29. Install the steering column shaft to flexible coupling. See Figure. Tighten flexible coupling bolt to specification. See TORQUE SPECIFICATIONS .
  30. Fill and bleed power steering system. See BLEEDING THE STEERING SYSTEM  under LUBRICATION.


  1. If new lines are to be installed, push the lines into new unions. See Figure.
  2. Push a new O-ring onto a Teflon Seal Expander, 211-D027 (D90P-3517-A) or equivalent. Position the Teflon Seal Expander, 211-D027 (D90P-3517-A) or equivalent, onto the union and install the O-ring seal. See Figure.
  3. Install power steering return line see Figure. Tighten the Steering Gear Cover Plate Retaining Bolts and Power Steering Tube Unions To Steering Gear Bolts to specification. See TORQUE SPECIFICATIONS .
  4. Install power steering high-pressure line support bracket. See Figure.
  5. Connect power steering high-pressure line union. See Figure.
  6. Push alignment pins through the subframe aligning holes. Engage locking pins. Using Subframe Alignment Pins, 502-002 (T94P-2100-AH), tighten the alignment pin sleeves to align the front subframe assembly. See Figure.
  7. Install front subframe assembly retaining bolts. See Figure.
  8. Loosen alignment pin sleeves. Disengage locking pins, and remove alignment pins from the subframe aligning holes. Remove special service tools. See Figure.
  9. Centralize rear support insulator and tighten mounting bolts to specification. See TORQUE SPECIFICATIONS . Install rear support insulator center bolt, and tighten to specification. Centralize rear support insulator. See Figure.
  10. Centralize the front support insulator and tighten nuts to specification. Tighten the front simulator center bolt to specification. See TORQUE SPECIFICATIONS . See Figure.
  11. Install secondary catalytic converter.
  12. Attach the fluid cooler lines retaining bracket. See Figure. Tighten bracket bolts to specification. See TORQUE SPECIFICATIONS .
  13. Attach bumper support brackets. See Figure. Tighten bracket bolts to specification. See TORQUE SPECIFICATIONS .
  14. Attach radiator splash shield. See Figure.
  15. Install front road wheels. Tighten wheel nuts to specification. See TORQUE SPECIFICATIONS .
    16. CAUTION: Before lowering the vehicle make sure that the steering is in the straight ahead position.
  16. Lower vehicle.
    17. WARNING: Install a NEW pinch bolt. Failure to follow this instruction may result in personal injury.
  17. Install steering column shaft flexible coupling. See Figure.
  18. Install floor seal. See Figure.
    19. WARNING: Install a NEW clamp bolt. Failure to follow this instruction may result in personal injury.
  19. Install steering column shaft to flexible coupling. See Figure.
  20. Connect power steering high-pressure line to power steering pump. Install power steering high-pressure line support bracket retaining bolt, and tighten to specification. See TORQUE SPECIFICATIONS . Connect power steering fluid reservoir hose to power steering pump, and connect power steering high-pressure line hose to the power steering pump. See Figure.
  21. Connect PSP switch electrical connector and install PSP switch. See Figure.
  22. Fill and bleed the power steering system. See BLEEDING THE STEERING SYSTEM  LUBRICATION.
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