Patient: 2003 Ford Excursion.

Tools needed:

10mm socket
18mm crowfoot wrench
Rachet + extensions
Small grips
1/2in breaker bar
Floor jack
2.5qts ATF

Optional:
Disposable gloves (lots of ATF)
Electric rachet
Impact wrench (if pulley is to be removed)
Wrench set (if pulley is to be removed)

Instructions:

Drain the P/S system. This is best done from the two hose connections under the radiator on the driver's side. Two hose clamps. As they are bottom of the loop, these will drain the system pretty thoroughly.



Second, remove the serpentine belt. Use a 1/2in break bar to push clockwise on the belt tensioner (located near bottom left of the alternator). Pull the belt off the pump pulley and store it up and out of the way.



Now the rest of the work is on your back. It's a tight working space but it's made easier if you remove the drag link from the pitman arm and tie it to the axle so it's out of your way. I didn't do it as this was my second removal and install of a pump in as many days.

First things first, the two hoses in and out of the pump. The larger of the two (return hose) is held on with just a hose clamp. That's easy, you've done two of those already! Just need a small pair of grips as, again, it's a tight working space.

Once that's done, the smaller hose (pressure hose) is held in by an 18mm nut. This can be a tough one, use PB Blaster and a crowfoot wrench + extension. It'll suddenly come loose and will inevitably surprise you.



Now the pump just needs to be removed from the manifold. There's 3 or 4 10mm nuts holding it in place. I only had three. I used my electric rachet here. Made life a lot easier. The top nuts are the hardest to reach as the pump gets in the way of itself. It's tight, which is why the electric rachet comes in handy.



Should go without saying, but support the weight of the pump on the last nut! That's it for the removal.

If you are swapping pulleys, this is where you'll need that impact wrench. I used O'Reilly's free loaner pulley removal kit. Reinstalling the pulley is just a case of two wrenches and a lot of sweat. Video instructions can be found in an abundance on YouTube.

I was removing the pump for a second time as I didn't swap pulleys from original to new pump. The new one was slightly bigger but still lined up. Didn't matter as it made my serp belt sing, so do yourself a favour, use your original pulley if in doubt!

Once complete, just reverse the above to reinstall. Again, the electric rachet makes hard work easy.



I used just the crowfoot wrench (without socket) to thread most of the pressure hose 18mm nut back into place.


Then I used the socket + extension to secure it.

Be mindful when reinstalling the serpentine belt as it's easily misaligned. Double-check all the pulleys or you'll be replacing a belt within a few moments after fire up.

Refill your P/S system.

I jacked the Ex up at this point, raising the front tires off the ground. Key on, engine off and turn the wheel lock-to-lock 15-20 times. Keep on eye on your P/S reservoir. You'll see the level drop a finger or two. This is expected as the fluid fills the box and lines again. Top off the reservoir and then start the engine. Be ready to pour in more fluid if necessary. Lock-to-lock again 10-15 times (never holding at the lock for more than a second).

That's it!

 

Nice pictures and write-up.

 

Well done, did you replace any hoses also?

 

I checked the lines and saw no reason to replace them. However, I'm wondering if I should've as my original issue has returned. Likely the aftermarket pump. Motorcraft going in next week!

 

I hear ya. With my 2nd pump in a month replaced with higher quality parts and new hoses, I’ve had no issues after 5 yrs.

 

Better on cold mornings too.

 

That looks like our winters too.

Say, which particular hoses did you replace, out of interest? Curious as there are several that make up the entire system.

 

I wish you could still buy new power steering pumps. Everything sold is a remanufactured pump, mostly with hit or miss quality.

 

Tell me about it. With all the aftermarket pumps out there - and the fact Motorcraft pumps are all remans anyway - this is why I threw in the towel and just got a salvaged part instead.

 

I replaced and got them all from RockAuto except the one from the reservoir to the pump- I recall diff diameter at each end.

 

This too will be added.

Stewart

 

I have replaced the power steering pump and have an issue. The high pressure hose doesn’t appear to tighten up. When I tighten the collar up, I can still rotate the hose. I have the new Teflon washer installed.

what am I missing?

 

If it's not leaking you are fine.

 

That hose is supposed to be able to move when the fitting is tight. As stated if it doesn't leak you are good.