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HOMESERVICE MANUALSFORD2005CUTAWAY 5.4 L, 5R110WREPAIR AND DIAGNOSISSTEERINGPOWER STEERINGSTEERING SYSTEM-GENERAL INFORMATIONDIAGNOSIS AND TESTINGSTEERING SYSTEMINSPECTION AND VERIFICATIONNOTES
2005 Ford Cutaway 5.4 L, 5R110W

Inspection and Verification: Notes

2005 Ford Cutaway 5.4 L, 5R110WSECTION Notes
  1. Verify the customer concern.
  2. Visually inspect for obvious signs of mechanical damage.
    VISUAL INSPECTION CHART

    Mechanical
    • Fluid level
    • Tire pressure
    • Tires
    • Drive belt
    • Drive belt tensioner
    • Steering column alignment
    • Tie rod ends
    • Suspension components
    • Steering column shaft U-joints
    • Intermediate shaft bolts
    • Power steering reservoir baffle
    • Power steering reservoir filter
    • Power steering pressure lines, fittings or O-rings
    • Power steering return hoses and clamps
    • Steering gear
    • Power steering pump
    3. NOTE: The areas that should be inspected for possible contamination are the power steering reservoir filter, flow control and pressure relief valve in the pump, and the check valve in the inlet port on the power steering gear (if equipped).
  3. Inspect the power steering fluid for the following conditions:
  4. Check the power steering system for fluid leaks.
    • Check the power steering fluid level.
    NOTE: It may be necessary to add power steering fluid to achieve the correct level.

    With the ignition OFF:

    • Wipe off the power steering pump, power steering pressure hose, power steering return hose, power steering fluid cooler, hose assembly and steering gear.
      • CAUTION: Do not hold the steering wheel at the stops for an extended amount of time. Damage to the power steering pump can occur.
    • Start the engine and turn the steering wheel from stop-to-stop several times and check for leaks.
  5. Inspect the power steering pressure and return hoses, fittings and O-rings for leaks.
    • If a leak is detected at a power steering pressure or return hose, install a new hose. Refer to POWER STEERING .
    • If a leak is detected between a fitting nut, seal the fitting nut using Teflon® joint seal.
    • If a leak is detected at a fitting, tighten to specification. If leak is still evident, visually inspect the fittings, O-rings and Teflon® seals. Install new as necessary. Refer to POWER STEERING .
    • If a leak is detected at the power steering reservoir, install a new reservoir. Refer to POWER STEERING .
    • If a leak is detected at a constant tension spring clamp, verify that the hose is fully installed on the fitting and that the hose clamp is correctly positioned. If the leak remains, install a new screw clamp.
    • If a leak is detected at a screw clamp joint, tighten the screw clamp. If the leak remains, inspect the tube end and install a new hose. Refer to POWER STEERING .
    • If a leak is detected at the power steering pump, install a new power steering pump. Refer to POWER STEERING .
  6. Inspect the power steering gear for leaks. If a leak is detected at the power steering gear, install a new power steering gear. Refer to POWER STEERING .
    Fig 1: Identifying Potential Power Steering Gear Box Leak Points
    G03884755Courtesy of FORD MOTOR CO.
  7. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
  8. If the cause is not visually evident, verify the symptom and GO to SYMPTOM CHART .
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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.