Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSFORD1996EXPLORER 4D UTILITY, 4.0 X, 4WD, AUTOMATICREPAIR AND DIAGNOSISSTEERINGPOWER STEERINGSTEERING SYSTEM - INTEGRAL POWER STEERINGTESTINGPRESSURE TESTPRESSURE/FLOW TEST
1996 Ford Explorer 4D Utility, 4.0 X, 4WD, Automatic
Pressure/Flow Test
1996 Ford Explorer 4D Utility, 4.0 X, 4WD, AutomaticSECTION Pressure/Flow Test
- With engine idling, record flow reading on analyzer gauge. Pump may need repair or replacement if minimum flow is less than 1.6 gallons (6.1L) per minute, go to next step.
- At idle, if pressure is greater than 150 psi (11 kg/cm2 ), check hoses for restrictions. Replace as required. Partially close analyzer gate valve to build up pressure to 740 psi (52 kg/cm2 ) for C-II pump.
- If flow drops to less than specification, disassemble pump and replace cam pack assembly. Replace pressure plates if cracked or worn.
- DO NOT
close analyzer gate valve for more than 5 seconds. Completely close, partially open gate valve 3 times. Record highest reading each time. If pressure not within specs, repair/replace flow control valve or pump. See PRESSURE/FLOW TEST SPECIFICATIONS
.PRESSURE/FLOW TEST SPECIFICATIONS
Application Min. Flow (1) Gal/Min. (Liter/Min.) Relief Pressure psi (kg/cm2 ) Ford C-II Pump .95 (3.4) 1050-1230 (74-86) (1) Partially close gate valve until pressure reaches 740 psi (52 kg/cm2 ) on C-II pumps. - Set engine speed at 1500 RPM. Record flow. If flow varies more than one gallon (3.8L) per minute from pressure measured in step 1), flow control valve in pump must be repaired or replaced.
- Turn steering wheel to left and right stops, holding at each stop for 3 seconds. Pressure should be nearly the same as maximum relief pressure. See PRESSURE/FLOW TEST SPECIFICATIONS . Flow should drop below .5 gallon (1.9L) per minute.
- If pressure and flow are not as specified, steering gear is leaking internally. Remove steering gear unit. Remove flow control valve. Repair or replace damaged parts. Check control valve seals for damage. See STEERING GEAR UNIT under OVERHAUL.
- If pressure and flow are good, turn steering wheel slightly in both directions and release quickly while watching pressure gauge. Needle should move from normal backpressure reading when steering wheel is turned, and needle should snap back as wheel is released. If gauge sticks or reacts slowly, rotary valve sleeve assembly in steering gear is sticking. Repair or replace rotary valve sleeve assembly.
- Check fluid for signs of contamination. If system is severely contaminated, disassemble and clean hoses, control valve and pump. After reassembly, if problem still exists, check ball joints, linkage and other front suspension components for seized and sticking parts.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.