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I bought my '99 F150 SC 4x4 5.4L about a year ago. Since about 4000 miles, the power steering has made a whine/gurgling noise. The dealer has seen it 4 times. Here is what the mechanic said:
VISIT 1-whine not duplicated
VISIT 2-pump whining extremely loudly, R & R breather assembly; replaced pump; purged air, refilled, etc.
VISIT 3-no problem found
VISIT 4-normal noise... contacted Ford and ran TSB... no TSB on this noise from Ford
So... my problem is that there IS a noise but it is small... meaning that if the air conditioner is on high and I have the radio on I can't hear it... BUT I don't like paying $26,000 for a truck that makes noises...
If any of you have any information on this, please email me about it. I want my truck to sound normal, not noisy. I am tired of people looking at me when I pull into a parking lot (although it is a really good lookin' truck).
I had an unusually load PS pump when I first bought my 99 F150 SC 4.6. I compared it to a friends F150 and another's Expedition, both of which had quiet PS pumps. I told my dealer to fix the noise because I had a Ford Probe years ago with a bad pump that led to the rack & pinion going bad too. Anyway, the dealer replaced the entire PS pump and my truck's fine. I think you said on your 2nd visit they replaced the pump. It's hard to figure out why a 2nd pump went bad, although if your 1st pump affected your rack & pinion any new PS pump will go bad because of metal flakes, debris, etc... getting recycled back into the new PS pump and eventually killing the new pump. That's what happened with my Probe. 4 PS pumps and a new rack & pinion later, everything was fine.