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it sounds like it is pumping too much pressure, you need to take the vehicle to a power steering specialist & have the pressure adjusted otherwise you will just keep bursting hoses or the seals on the steering rack......hope this helps.....cheers.
The steering is extremely heavy if the power steering has failed and it is VERY DANGEROUS to attempt to drive the car in this condition. The car was not designed to be steered without the power assistance. You should not attempt it and the vehicle is NOT roadworthy. You will impair your insurance coverage if you knowingly drive the vehicle in this condition and expose yourself to criminal charges if you injure anyone.
The cost of repair depends entirely on the nature of the fault, the parts prices and labor rates charged at different workshops. If the problem is a result of a leaking/damaged power steering hose that needs replacing the costs will be moderate. If the power steering pump has failed and needs replacing it will be more expensive in labor and parts.
You need to find a competent mechanic familiar with Chevs and have the car towed to his premises for repair. The car needs to be put on a hoist to be properly inspected and repaired competently.
Alternatively you could try one of the mobile auto repair services if you have one operating in your area.
On a 1996 3.8 L Should be under the power steering on the block. Looking at the pulleys on the right side just above the oil pan. This would involve removing the pwr steering punp and hoses.
I don't know if a 2003 is different.. You could inspect the area visually to check it.
To get to replace it...
96 - 98 windstar 3.8 oil pressure switch is located under power steering pump. Remove serpentine belt and alternator. Remove PS pump pulley with special puller to get access to PS pump bolts. Drain PS pump and remove PS hoses. Remove PS pump.
WARNING: THE ELECTRICAL CIRCUIT NECESSARY FOR SYSTEM DEPLOYMENT IS POWERED DIRECTLY FROM THE BATTERY . TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE POSITIVE BATTERY CABLE MUST BE DISCONNECTED PRIOR TO SERVICING OR REPLACING ANY SYSTEM COMPONENTS.
Disconnect the positive battery cable and wait one minute for backup power supply energy to be depleted.
Remove the drive belt. Remove the generator. Remove the power steering pump pulley as described.
Position the drain pan. Remove the power steering pressure hose and the power steering return hose from the power steering pump .
Remove the idler pulley.
On vehicles equipped with A/C, remove the A/C compressor brace.
Remove three bolts and the power steering pump and bracket assembly.
Remove the retaining bolts and power steering pump from the power steering pump support .
To install, reverse the removal procedure.
Tighten the power steering pump bolts to 40-55 Nm (30-40 lb-ft).
Tighten the power steering bracket bolts to 40-55 Nm (30-40 lb-ft).
Tighten the A/C compressor brace nut to 20-25 Nm (15-18 lb-ft).
Tighten the idler pulley bolt to 40 Nm (30 lb-ft).
Section 03-01B: Engine, 3.8L
1996 Windstar Workshop Manual
SPECIAL SERVICE TOOL(S) REQUIRED
Fuel Line Disconnect Tool Set
Drain engine cooling system. Refer to Section 03-03 .
Loosen drive belt tensioner (6B209) and remove drive belt (8620). Refer to Section 03-05 .
Raise vehicle on hoist. Refer to Section 00-02 .
Disconnect lower radiator hose (8286) from radiator lower hose tube (8291) and radiator (8005).
Disconnect radiator lower hose tube from water pump (8501).
Remove lower nut on both front engine support insulators (6038).
Disconnect battery ground cable (14301). Refer to Section 14-01 .
Remove generator (GEN) (10346) from power steering pump support (3C511).
Position drain pan and disconnect power steering pressure line from power steering pump (3A674) using Fuel Line Disconnect Tool Set T90T-9550-S.
Remove power steering reservoir filler cap.
CAUTION: If using a prying device to assist in water pump removal, be careful not to damage the mating surfaces.
Disconnect water bypass hose (8597) and oil cooler hose (6B850) from heater water outlet tube (18663).
Remove retaining bolts and disconnect heater water outlet tube from water pump.
Remove A/C bracket brace.
Attach engine lifting eye to left-hand (front) exhaust manifold (9430).
Attach lifting equipment to engine lifting eye and raise front of engine approximately 51 mm (2.0 inches) to provide necessary clearance for water pump removal.
Remove water pump pulley retaining bolts and water pump pulley (8509).
Remove drive belt tensioner pulley retaining bolt and drive belt tensioner pulley (6B217) from power steering pump support.
Remove power steering pump support retaining bolts and nut. Place power steering pump and support assembly aside in a position to prevent fluid leakage.
Remove water pump retaining bolts and nuts and water pump. Discard used water pump housing gasket (8507).
NOTE: Lightly oil all bolt and stud bolt threads before installation except those specifying special sealant.
Clean gasket surfaces on water pump and engine front cover (6019).
NOTE: The threads of the No. 1 engine front cover retaining stud must be coated with Pipe Sealant with Teflon® D8AZ-19554-A or equivalent meeting Ford specification WSK-M2G350-A2 before installing.
NOTE: Gasket and Trim Adhesive D7AZ-19B508-B or equivalent meeting Ford specification ESE-M2G52-A is recommended to hold the water pump housing gasket in position.
Position a new water pump housing gasket on water pump housing sealing surface.
Position water pump on the engine front cover. Install retaining bolts.
Position power steering pump support and install retaining nuts and bolts. Tighten bolts and nuts to 40-55 Nm (30-40 lb-ft).
Install drive belt tensioner pulley and retaining bolt. Tighten bolt to 70-95 Nm (52-70 lb-ft).
Install A/C bracket brace.
Position water pump pulley on water pump hub and install retaining bolts. Tighten bolts to 8.0-11.5 Nm (71-101 lb-in).
Lower engine and disconnect lifting equipment from lifting eye.
Remove lifting eye from exhaust manifold.
Connect heater water outlet tube to water pump and install retaining bolts. Tighten bolts to 8-11.5 Nm (71-101 lb-in).
Connect water bypass hose and oil cooler hose to heater water outlet tube. Tighten clamps securely.
Connect power steering pressure line to power steering pump fitting.
Install power steering reservoir filler cap.
Install generator to power steering pump support. Refer to Section 14-02 .
Connect battery ground cable. Refer to Section 14-01 .
Raise vehicle on hoist. Refer to Section 00-02 .
Install lower nut on front engine support insulators and tighten retaining nut to 88-119 Nm (65-87 lb-ft). Install lower nut of rear engine support insulator and tighten to 77-104 Nm (56-76 lb-ft).
Connect radiator lower hose tube to water pump. Install retaining bolt and tighten securely.
Connect lower radiator hose to radiator lower hose tube and radiator. Position hose clamps securely. Refer to Section 03-03 .
Position drive belt over drive belt tensioner and release drive belt tensioner. Refer to Section 03-05 .
CAUTION: This engine has aluminum cylinder heads (6049) and requires a special corrosion inhibiting coolant to avoid cooling system damage. Refer to Section 03-03 for the coolant specifications.
Fill and bleed cooling system with specified coolant.
Fill power steering pump reservoir with specified fluid.
Start engine and check for coolant and power steering fluid leaks. Service as necessary.
i pERSONALY WOULD REPLACE IT MYSELF EVEN WITHOUT MY 30yrs Of Experience in this Field. I have Enclosed Instructions for you to use. PLEASE dont Forget to RATE me As MOST folks DONT remember to that is how WE Get our Ratings such as GURU THANK YOU and Good Luck On The Job, Dont PAY a dime If YOU CAN > D I Y
Remove the power steering pressure hose (2) from the power steering pump (1).