Steering - Moan/Grunt Noise Mainly on Left Turns
TSB 04-23-811/29/04
STEERING GEAR NOISE - 6.0L DIESEL ENGINE
FORD:
2004 Excursion, F-Super Duty
ISSUE
Some 2004 F-Series Super Duty and Excursion vehicles equipped with the 6.0L diesel engine, may exhibit a moan/grunt noise coming from the power steering when turning the steering wheel. The condition is typically more pronounced during left hand turns. The noise may sound like it is coming from the steering gear or the steering column area.
ACTION
Replace the hydraulic booster to steering gear pressure line and the cooler to steering gear return line. Refer to the following Service Procedure.
SERVICE PROCEDURE
NOTE
WHEN REPAIRING THE POWER STEERING SYSTEM, CARE SHOULD BE TAKEN TO PREVENT CONTAMINANTS FROM ENTERING THE SYSTEM AS PREMATURE FAILURE OF THE POWER STEERING COMPONENTS CAN RESULT. ALWAYS THOROUGHLY CLEAN ALL DEBRIS FROM THREADS AND FITTINGS DURING DISASSEMBLY/REASSEMBLY.
HYDRAULIC BOOSTER TO STEERING GEAR PRESSURE LINE REPLACEMENT
1. Using a suitable suction device, drain the power steering fluid reservoir.
2. Disconnect the pressure line-to-booster fitting (Figure 1).
3. Remove the air cleaner assembly and the steering gear cover.
4. Disconnect the pressure line-to-steering gear fitting and remove the pressure line.
5. Remove the adaptor fitting from the new pressure line (located on the end of the line that goes into the steering gear) and install the adaptor into the steering gear, torque adapter to 26 lb-ft (35 N.m).
6. Install the pressure line into the hydraulic booster unit. Hand tighten the tube nut (M16 with longer hex lands).
7. Route the line to the steering gear as shown in (Figure 2).
8. Hand tighten tube nut into previously installed adaptor fitting.
9. Orient the line as shown in Figure 2. Torque each tube nut to 26 lb-ft (35 N.m).
COOLER TO STEERING GEAR RETURN LINE REPLACEMENT
1. Remove the clamp and disconnect the hose from the cooler to gear line (Figure 3).
2. Disconnect clip from radiator support and discard push pin. Remove the clip from the line. CLIP TO BE REUSED.
3. Disconnect the line from steering gear (Figure 4).
4. Discard the 0-ring seal.
5. Hand tighten the new line tube nut into the steering gear.
6. Position the cooler-to-gear line into clip. Reposition cooler to reservoir line so that there is no contact between the two lines near the gear. Close clip and reattach clip to radiator support using new push pin (390018-S).
7. Install cooler hose onto line, make sure it is fully seated all the way to stop bead. Position spring clamp so that it is between 1/8 to 3/16" (2-4 mm) from the end of the hose.
8. Torque tube nut at gear to 26 lb-ft (35 N.m).
9. Install gear box cover and air cleaner assembly.
10. Refill the system with clean fluid.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
042308A Replace The Hydraulic 1.3 Hrs.
Booster To Steering Gear
Pressure Line And The
Cooler To Steering Gear
Return Line (Includes Time
To Fill And Bleed Power
Steering System)
DEALER CODING
CONDITION
BASIC PART NO. CODE
3504 42
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