[Andy_W]

I did a search but nothing really matched my symptoms...

I recently had my PS pump fail (it had a small leak for over a year but finally gave out...constant whine, loss of all PS and hydroboost).

So I replaced the PS pump with a reman from OReilly. It fit fine...was a PITA to replace but everything worked when I powered back up and there were no leaks.

I did execute the purge procedure from the Ford manual (I have the official service manuals) for purging the system (vacuum, cycle brakes, 10 steering cycles, etc) and the system appeared to be fine for about four days.

Two days ago it started whining at startup for about 5-10 sec. So I executed the purge procedure again. Seemed to fix it, but now, after driving for about 15 minutes, the pump will start whining again and PS and hydroboost is affected. The weird thing is that if I drive in a tight circle left and then right, the whining stops and everything works fine for a few minutes. Also, if I hold down the brake pedal hard (actuate hydroboost) the whining stops, which was the opposite of what happened when the pump had failed.

The system still has no leaks and I filled it with a high quality Mercon V (AMSOIL) and purged a gallon after replacing the pump to ensure as much of the old fluid was gone as possible.

One thing I did notice when doing the vacuum test was the the hose from the reservoir to the pump collapses a good bit when doing a vacuum test and that hose is much less stiff than the other hoses. Could that restriction be occurring when the system warms up, causing the pump to be starved during load? I intend to replace that hose today to see what happens but would appreciate anyone's insight into these symptoms. I don't think it is the steering gear as the symptoms are also effected by hydroboost load (brakes) in the same way, so it would lead me to believe it is something common. TIA.

P.S. Looking at the symptom chart in the manual, it lists blockage in the PS reservoir as a potential cause. This wasn't a problem when I disconnected the pump (had plenty of flow from that line...lol) but I'll remove it and check.

 

[Andy_W]

This job is becoming so time consuming and perplexing...now the system makes no noise and works fine (brakes are noticably stronger) EXCEPT when stopped or a very low speed...then it is like there is almost no PS assist. I troubleshot via the manual and RPM doesn't change it and it specifies a flow rate test (with gear I don't have, of course). I am about to just replace the PS pump again.

What i did:

I removed, inspected, and cleaned the reservoir (no obstructions, no filter), no issues. plenty of flow.

I replaced the hose from the reservoir to the pump. It doesn't collapse under vacuum like the factory one I removed.

I did a flush per the standard DIY procedure (connect to the hydroboost outlet method) and flushed 3 quarts. Only difference is that this time, I used the affordable NAPA-branded MERCON V not the expensive AMSOIL I had put in last week when I replaced the pump.

I did the factory purge procedure, no problems.

So, I suppose it could be one of three things:

1. Replacement PS pump is a lemon
2. NAPA MERCON V sucks.
3. Steering gear has an issue
4. Something else???

The inconsistency of the symptoms is really what throws me. What would you try next?

 

[Andy_W]

Well, I realize I appear to be having a conversation only with myself but figured I'd close this out. It appears the answer was "#1", lemon PS pump. Replacing the PS pump a second time appears to have restored everything to normal. No whine. Easy to steer at any speed, including stopped, brakes work great. Whew! What a pain this job was...

 

[crashz]

I've found that replacement components from box stores are very unreliable. Even better parts houses like NAPA have high failure rates right out of the box. Had a heck of a time with alternators and water pumps a few years ago and began buying factory or upgraded parts. Prices are higher but I compare them with the cost of doing the job over again and my limited amount of free time.

Glad you have your rig back together.

 

[Andy_W]

I've found that replacement components from box stores are very unreliable. Even better parts houses like NAPA have high failure rates right out of the box. Had a heck of a time with alternators and water pumps a few years ago and began buying factory or upgraded parts. Prices are higher but I compare them with the cost of doing the job over again and my limited amount of free time.

Yep, next time I get Motorcraft.

Glad you have your rig back together.

Unfortunately, not quite....Serpentine ate itself on the way to work today. Gonna check the alignment of the PS pulley tonight...possible contributor. Belt had over 30k on it and ATF exposure...not sure what that does to the belt. Anyway, so I went and got everything for belts from my local dealer (they matched online prices!) for replacing both belts vice the auto part stores. Got both tensioners, both idlers, both belts...Man, I just want to be done working on this thing for a bit...sigh.

 

[Andy_W]

So the saga continues...removed the belts, tensioners, and idlers without removing the fan clutch. But when I reinstall the new ones, the tension due to the pins on the AC tensioner makes it so I cannot get torque on it to release the tension and remove the pin. Rented the tools to remove the fan clutch but the tool that holds the water pump bolts was too hard to keep in place and the one wrench that did fit the fan clutch not was the ONLY one in the git without a socket driver hole so you could attach a breaker bar. Ended up using a floor jack and two ratchet extensions to push the tensioner from below.

I also tightened down the PS pump pulley more. It is better aligned now, but now I have a NEW problem...a metallic clicking from the PS pump (it goes away if you turn the wheel). Video with the sound is below. I think I will just bite the bullet and get a real Motorcraft part and pulley. This "simple" PS replacement job has now cost about $600 in parts and tools...plus a measurable amount of my sanity!

http://www.drivehq.com/file/df.aspx/...Spumpclunk.mp4