Steering - Shudder on Low Speed Turns
TSB 05-17-1509/05/05
STEERING SHUDDER DURING LOW SPEED
MANEUVERS - 4.0L ENGINE
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
1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer to Workshop Manual, Section 211-02.
2. 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.
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 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 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. 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.
5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section 211-00.
6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release B28.5 or higher. Calibration files may also be obtained at the website.
VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001
NOTE
FOR ALL 4X2 SPORT TRAC VEHICLES BUILT AFTER 4/18/2001, PROCEED DIRECTLY TO STEP 2. THESE VEHICLES ARE ALREADY EQUIPPED WITH THE HIGH OUTPUT DISPLACEMENT PUMP (5L2Z-3A674-CA).
1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer to the Workshop Manual, Section 211-02.
2. 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.
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 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 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. 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 2). Reattach the power steering pressure hose to the inlet of the steering gear.
5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section 211-00.
6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release B28.5 or higher. Calibration files may also be obtained at the website.
VEHICLES BUILT AFTER NOVEMBER 7, 2001
1. Remove the power steering cooler (Figure 3) from the steering gear.
2. Remove the return line from the power steering reservoir bottle (Figure 4).
3. Remove the return line from the steering gear (Figure 5).
4. Replace the current cooler (3D746) and two return lines (3A713 and 3A005) with a fin pack cooler assembly (5L2Z-3D746-A).
5. Fill and purge the P/S system following the procedures called out in the on-line Workshop Manual Section 211-00.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
051715A 2001 Explorer Sport Trac 2.2 Hrs.
4X214X4, Explorer Sport
4X214X4 Vehicles Built
Before 4-18-2001: Replace
The Power Steering Pump,
P/S Cooler, Install No Hole
Check Valve, Fill And
Purge The P/S System,
Reprogram The Powertrain
Control Module (Do Not
Use With 3504A, 3504A9,
3674A, 3674D)
051715A 2001-2002 Explorer Sport 2.2 Hrs.
Trac 4X4, Explorer Sport
4X214X4 Vehicles Built
After 4-18-01 And Before
11-7-2001: Replace The
Power Steering Pump, P/S
Cooler, Install No Hole
Check Valve, Fill And
Purge The P/S System,
Reprogram The Powertrain
Control Module (Do Not
Use With 3504A, 3504A9,
3674A, 3674D)
051715B 2001-2002 Explorer Sport 1.4 Hrs.
Trac 4X2 Built After
4-18-2001: Replace The
P/S Cooler, Install No Hole
Check Valve, Fill And
Purge The P/S System,
Reprogram The Powertrain
Control Module (Do Not
Use With 3504A, 3504A9,
3674A, 3674D)
051715C 2002-2005 Explorer Sport 1.0 Hr.
Trac 4X2/4X4 Explorer
Sport 4X2/4X4 Built After
11-7-2001: Replace The
P/S Cooler, Fill And Purge
The P/S System (Do Not
Use With 3504A, 3504A9,
3674A, 3674D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
3A674 42
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