Cant get the bracket off a 1996 ford windstar for the power steer
I have got the lines free. alternator off, what I thought were all the bolts out just wont go. It will move front to back so there must be 1 more bolt is it behind the pulley ? Just to the left of the pulley there is a long one it is removed what ever is holding me up is at the pulley neer front of van
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Power Steering Pump - 4.0L
Installer Set, Teflon® Seal
211-D027 (D90P-3517-A) or equivalent
MERCON® V Automatic Transmission Fluid
XT-5-QM (or XT-5-QMC) (US); CXT-5-LM12 (Canada)
Pressure line-to-pump fitting (part of 3A719)
Power steering pump bolts (3 required)
Power steering pump
Pressure line bracket-to-engine bolt
Power steering pump supply hose
Power steering pump supply hose bracket bolt
Removal NOTICE: While repairing the power steering system, care should be taken to prevent the entry of foreign material or failure of the power steering components may result.
Using a suitable suction device, remove the power steering fluid from the reservoir.
With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02.
Give the model and year at an autoparts store and ask for a power steering belt. Will likely be running the waterpump and alternator too so you cant drive far because you will overheat the engine and or flatten your battery.
Loosen alternator bracket all bolts and move it to the shortest distance to the nearest pulley wheel. Slide belt around all free wheels and idlers (tensioning wheels) and move alternator bracket back to original position so belt is tight.
If you cant get the belt on belt is too short, if it is not tight with alternator about half way along the adjustment bracket belt is too long. Take it back to store, act real grumpy, try to leave with right size belt and a free gift.
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).
RH side of engine compartment by firewall
1. Disconnect the battery ground cable.
2. remove the drive belt (Serpentine belt)
3. Remove the power steering hose bracket from the alternator bracket.
4. Remove bolts hold alternator to bracket
5. Disconnect the alternator electrical connectors
Before servicing the vehicle refer to the precautions at the beginning of this section.
Disconnect the battery ground cable.
Remove the accessory drive belt.
Remove the alternator.
Drain and remove the radiator coolant recovery reservoir.
Position a drain pan under the power steering pump underneath the vehicle. Disconnect the hydraulic pressure and return lines and allow to drain.
Remove the idler pulley from the power steering pump support.
Remove the belt tensioner.
Remove the bracket mounting bolt located under the belt tensioner mounting.
Remove two retaining nuts from the bracket mounting studs. Remove both mounting studs, and pull off the power steering pump support with the pump attached.
Clamp the pump support bracket in a suitable vise.
Remove the power steering pump pulley from the pump shaft using Pump Pulley Remover T69L-10300-B, or equivalent. Remove the three bolts retaining the power steering pump to the power steering pump support and remove the power steering pump.
To Install: NOTE: The pulley must be installed within 0.010 in (0.25 mm) flush with the power steering pump shaft.
Install the power steering pump to the power steering pump support. Tighten the mounting bolts to 18 ft-lb. (25 Nm).
Install the power steering pump pulley using Steering Pump Pulley Replacer T65P-3A733-C, or equivalent; the pulley face must be flush within 0.010 inch (0.25mm) of the pump shaft.
Install the power steering pump/pump support and torque nuts/bolt to 24 ft. lbs. (33 Nm).
Install the bracket mounting bolt located under the belt tensioner mounting.
Install the belt tensioner.
Install the idler pulley to the power steering pump support.
Connect the hydraulic pressure and return lines.
Install the radiator coolant recovery reservoir.
Install the alternator.
Install the accessory drive belt.
Fill the power steering reservoir with power steering fluid.
Connect the battery ground cable.
Run the engine and check for leaks and proper operation. Bleed the power steering system if needed.
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.