Steering - Shudder on Low Speed Turns or When Stopped
Article No.03-19-12
09/29/03
^ STEERING - STEERING SHUDDER - FELT WHEN
TURNING - DRIVING AT SLOW SPEEDS OR AT STOP
^ VIBRATION - STEERING SHUDDER - FELT WHEN
TURNING - DRIVING AT SLOW SPEEDS OR AT
STOP
FORD:
2001-2003 EXPLORER SPORT
2001-2004 EXPLORER SPORT TRAC
This article supersedes TSB 01-25-01 to update the part numbers and the vehicle coverage.
ISSUE
Some 2001-2004 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 by 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. Per the vehicle build date it may be necessary to replace the power steering pump and cooler, and install a no-hole check valve in the steering gear. Perform a thorough evacuation of air from the power steering system after replacement/installation of parts and reprogram the Powertrain Control Module (PCM) to the latest level calibration.
NOTE
THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED OF AIR WITH A VACUUM AT THE RESERVOIR. CORRECTLY FOLLOWING THE EVACUATION PROCEDURE DETAILED BELOW WILL REDUCE THE AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER. THE SHUDDER MAY STILL BE PRESENT AFTER REPLACEMENT OF THE PARTS IF THE EVACUATION PROCEDURE IS NOT PROPERLY FOLLOWED.
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.
SERVICE PROCEDURE
VEHICLES BUILT PRIOR TO APRIL 18, 2001
1. Replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions.
NOTE
DO NOT FILL, PURGE, OR LEAK CHECK THE SYSTEM AT THIS POINT SINCE THE STEERING GEAR CHECK VALVE AND COOLER MUST ALSO BE REPLACED.
2. Replace the Cooler Assembly with service part F77Z-30746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures).
BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions.
3. 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 flow out of 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 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL-211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E60Z-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. 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 (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear.
5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent.
6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill.
7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction.
NOTE
AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED.
8. Recheck the fluid level and, if necessary, refill.
9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns.
10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine.
NOTE
THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP.
11. Reprogram the PCM to the latest level available.
12. Test drive to verify repair.
VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001
1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump (Part Number 1L2Z-3A674-GA) and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions.
2. Replace the Cooler Assembly with service part F77Z-3D746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures).
BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions.
3. 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 flow out of 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 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE.
4. 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 that is present in the current check valve.
CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. 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 (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear.
5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent.
6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill.
7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction.
NOTE
AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED.
8. Recheck the fluid level and, if necessary, refill.
9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns.
10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine.
NOTE
THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP.
11. Reprogram the PCM to the latest level available.
12. Test drive to verify repair.
VEHICLES BUILT AFTER NOVEMBER 7, 2001
WARNING
DO NOT INSTALL THE CHECK VALVE ON VEHICLES BUILT AFTER 11/07/2001. TRYING TO INSTALL THE CHECK VALVE WILL CAUSE DAMAGE TO THE RACK AND IT WILL HAVE TO BE REPLACED.
1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions.
2. Check and fill the power steering reservoir as necessary with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent.
3. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill.
4. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction.
NOTE
AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED.
5. Recheck the fluid level and, if necessary, refill.
6. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns.
7. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine.
NOTE
THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP.
8. Reprogram the PCM to the latest level available. (Does not apply to 2003-2004 vehicles)
9. Test drive to verify repair.
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
PCM Calibration Information
Parts Block
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 01-25-1
WARRANTY STATUS: Eligible Under Provisions Of The New Vehicle Limited Warranty.
OPERATION DESCRIPTION TIME
031912A Replace Power Steering 2.4 Hrs.
Pump, P/S Cooler, Install
No Hole Check Valve,
Bleed Air From P/S
System, Reprogram PCM
Vehicles Built Prior To
4-18-01 4x4 Explorer Sport
Trac And 4x2/4x4 Explorer
Sport
031912B Replace Power Steering 2.5 Hrs.
Pump, P/S Cooler, Install
No Hole Check Valve,
Bleed P/S System,
Reprogram PCM (Includes
Time To Bleed Air From
P/S System A Second
Time) Vehicles Built Prior
To 4-18-01 4x4 Explorer
Sport Trac And 4x2/4x4
Explorer Sport
031912C Replace Power Steering 1.6 Hrs.
Cooler, Install No Hole
Check Valve, Bleed Air
From P/S System,
Reprogram PCM Vehicles
Built After 4-18-01 But
Prior To 11-07-01 4x2
Explorer Sport Trac
031912D Replace Power Steering 1.8 Hrs.
Cooler, Install No Hole
Check Valve, Bleed Air
From P/S System,
Reprogram PCM (Includes
Time To Bleed Air From
P/S System A Second
Time) Vehicles Built After
4-18-01 But Prior To
11-07-01 4x2 Explorer
Sport Trac
031912E Replace Power Steering 1.9 Hrs.
Pump, Bleed Air From P/S
System, Reprogram PCM
Vehicles Built After
11-07-01 But Before
8-19-02 4X4 Explorer Sport
Trac/4x2 Or 4x4 Explorer
Sport
031912F Replace Power Steering 2.0 Hrs.
Pump, Bleed Air From P/S
System, Reprogram PCM
(Includes Time To Bleed
Air From P/S A Second
Time) Vehicles Built After
11-07-01 But Before
8-19-02 4x4 Explorer Sport
Trac/4x2 Or 4x4 Explorer
Sport
031912G Bleed Air From P/S 1.1 Hrs.
System, And Reprogram
PCM Vehicles Built After
11-07-01 But Before
8-19-02 4x2 Explorer Sport
Trac
031912H Bleed Air From P/S 1.2 Hrs.
System, And Reprogram
PCM (Includes Time To
Bleed Air From P/S A
Second Time) Vehicles
Built After 11-07-01 But
Before 8-19-02 4x2
Explorer Sport Trac
031912I Replace Power Steering 1.4 Hrs.
Pump, Bleed Air From P/S
System Vehicles 8-19-02
Or After 4x4 Explorer
Sport Trac, 4x2 Or 4x4
Explorer Sport
031912J Replace Power Steering 1.8 Hrs.
Pump, Bleed Air From P/S
System, (Includes Time To
Bleed Air From P/S A
Second Time) Vehicles
Built 8-19-02 Or After 4x4
Explorer Sport Trac, 4x2
Or 4x4 Explorer Sport
031912K Bleed Air From P/S 0.6 Hrs.
System, Vehicles Built
8-19-02 Or After 4x4
Explorer Sport Trac, 4x2
Or 4x4 Explorer Sport
031912L Bleed Air From P/S 1.0 Hrs.
System, (Includes Time To
Bleed Air From P/S A
Second Time) Vehicles
Built 8-19-02 Or After 4x4
Explorer Sport Trac, 4x2
Or 4x4 Explorer Sport
DEALER CODING
CONDITION
BASIC PART NO. CODE
3A674 42
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