Fill Procedure

DESCRIPTION
This procedure is recommended whenever the power steering pump or power rack and pinion steering gear is removed, serviced and installed into the power steering hydraulic system.

MATERIALS REQUIRED
1. A vacuum pump with gauge, capable of pulling 101 kPa (30 in. Hg). The vacuum source should be one of the following:
^ Distributor test machine vacuum pump.
^ Vacuum motor from an air conditioning charging system.
2. A No.7 stopper cap or a special power steering reservoir pump cap assembly with a hose connection.

PREPARATION
1. If the power steering short rack or power steering pump has been changed or flushed, allow old fluid to drain from the system.
2. Tighten all steering system connections.

INITIAL FILL
1. Install the cap on the power steering pump fill neck or rubber stopper on power steering oil reservoir.
2. Open Valve No. 1 and allow the power steering fluid to bleed through the tee fitting. Close Valve No. 1 after bleeding.
3. Pour enough Premium Power Steering Fluid E6AZ-19582-AA or equivalent meeting Ford specification ESW-M2C33-F in the power steering pump reservoir to exceed the amount required for filling the system.
4. Close all valves.
5. Open Valves No. 2 and No. 3. Start the vacuum pump. Operate the pump until a gauge reading of 84-101 kPa (25-30 in. Hg) is obtained.
6. Close Valve No. 3 and shut off the vacuum pump. Watch the gauge for approximately 30 seconds. If the vacuum reading drops more than 1 in. Hg (3 kPa), there is a leak in the power steering or filling system that must be corrected.
7. Start the vacuum pump. Open Valve No. 3. Operate the pump until a gauge reading of 84-101 kPa (25-30 in. Hg) is obtained.
8. Close Valve No. 2 and shut off the pump. Open Valve No. 1 to fill the steering system with fluid. The power steering pump reservoir should be elevated higher than the power steering pump and power steering oil reservoir.
9. When fluid stops draining from power steering pump reservoir, close Valve No. 1 and remove cap or rubber stopper.

FINAL FILL
1. Adjust fluid level in power steering pump to correct level. There will be a slight drop in the level when the engine is first started and the steering wheel is cycled.
2. Operate the engine at an idle for 15 minutes, then inspect for leaks. It will not be necessary to devac the system unless there is evidence of air in the power steering pump that could cause noise or affect performance.