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The replacement idler pulley could be defective. This is a frequent failure item in Ford products of that vintage. The belt could have gotten worn by a wobbly pulley. The replacent pulley could have been installed without making any adjustment.
1) Gather the materials -- Instructable step 1 - This includes tools, a new pump, fluids, etc. 2) Remove the leaking pump -- Instructable step 2 - Drain the Power Steering system -- Instructable step 3 - Remove accessories from Power Steering system -- Instructable step 4 - Remove the pulley and bolts -- Instructable step 5 - Remove power steering pump 3) Install the new pump -- Instructable step 6 - Place the new power steering pump -- Instructable step 7 - Press on the power steering pump pulley -- Instructable step 8 - Align the pulley and attach the belts -- Instructable step 9 - Flush and fill the power steering system 4) Cleanup -- Instructable step 10 - Cleanup
You'll need some tools to complete this task. Before you start, gather the necessary equipment -- you will not be able to use the car once you start the replacement! It is always a good idea to have a friend on call, or a second car available.
Power Steering pump (to replace defective pump)
Two (2) quarts power steering fluid or appropriate ATF (to flush and fill). More than 2 quarts if flushing the rack is desired.
Power Steering Pulley Puller set (to remove and attach the pulley). Some auto parts stores will loan the tool sets.
Open end wrench set (for use with puller set).
Leverage pipe or extension bar (in case the pulley is hardened on the spindle).
Drain pan (to drain & flush power steering system).
Wheel bearing grease for sliding pulley on the pump hub.
2' wood 1x2 for assistance with aligning the pulleys. Any straight tool will work fine -- a level, metal rod, wood, whatever.
Check for low power steering fluid, a broken belt (there is a belt that connects the engine's main drive pulley to the power steering, alternator, air conditioning, etc. pulleys) or your power steering pump went bad and will need to be replaced.
You will probably need to realign the pulleys. It sounds like one of them might be out too much. Try taking a straight edge of some sort on the power steering pump and see if it is aligned with the other pulleys. Good luck!
May have a failure in the replaced rack. I would take it back to the shop that did the work for warranty. If you got a remanufactured rack it was re-built and may have had major problems that were not fixed with the rebuild.
Don't know if this helps. Had squeel in belt area. Occasionally engine would stop when squeel got loud and sometimes engine would try to quit while going at various speeds. Found tensioner pulley was bad and changed it. Still squeeled and engine would stop when squeel got loud. This time while sitting in yard. Further checking found binding in power steering pump. Will be putting on new one tomorrow. Hope it works. Will update.
they make a uv dye you can put in there and run it till it leaks and you put on the glasses and shine the light that comes in the kit arund and where it is leaking will glow but it sounds like the leaks are just the rad hoses or heater core hoses