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Steering System > < 211-00 Steering System - General Information|Specifications

Focus 2004.75 (07.2004-)

Steering System - General Information - Steering System—1.6L Duratec-16V (Sigma) Focus 2004.75 (07/2004-)
Diagnosis and Testing

Special Tool(s)

Alignment Pins, Subframe

205-316 (15-097A)

Simulator, Driver and Passenger Air Bags and Side Air Curtains

501-073 (40-016)
General Equipment
Worldwide Diagnostic System (WDS)

Inspection and Verification

  1. Verify the customer concern.
  1. Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection Chart

Mechanical Electrical
  • Tire pressure(s)
  • Accessory drive belt
  • Loose tie-rod end(s)
  • Tie-rod(s)
  • Steering gear housing
  • Loose strut and spring assemblies or ball joints
  • Loose pinch bolts on steering column shaft flexible coupling
  • Wheels and tires
  • Power steering line fluid leaks
  • Steering gear bellows
  • Power steering pressure (PSP) switch
  1. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
  1. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart.

Symptom Chart

Symptom Chart

Symptom Possible Sources Action
Drift left or right
*
Vehicle attitude incorrect (front or rear is high or low).
*
CHECK for abnormal loading, coil spring sag or non-standard springs.
*
Incorrect wheel alignment.
*
CHECK the wheel alignment and ADJUST if necessary. REFER to: (204-00 )
Specifications (Specifications),
Front Toe Adjustment (General Procedures).
*
Incorrect front axle crossmember alignment.
*
Using the special tool, Check the front axle crossmember alignment.
*
Worn front wheel bearings.
*
CHECK and INSTALL new wheel hubs as necessary.
REFER to: Wheel Hub (204-01, Removal and Installation).
*
Brake system.
*
CHECK the brake system.
REFER to: Brake System (206-00, Diagnosis and Testing).
*
Steering linkage.
*
CARRY OUT the Steering Linkage Component Test. REFER to Steering Linkage Component Test.
*
Steering gear.
*
CARRY OUT the Steering Linkage Component Test. REFER to Steering Linkage Component Test.
*
Wheels and tires.
*
REFER to: Wheels and Tires (204-04, Diagnosis and Testing).
Steering wheel off center
*
Vehicle attitude incorrect (front or rear is high or low).
*
CHECK for abnormal loading, coil spring sag or non-standard springs.
*
Incorrect wheel alignment.
*
CHECK the wheel alignment and ADJUST if necessary. REFER to: (204-00 )
Specifications (Specifications),
Front Toe Adjustment (General Procedures).
*
Suspension lower arm ball joint.
*
CARRY OUT the Ball Joint Inspection Component Test.
REFER to: Suspension System (204-00, Diagnosis and Testing).
*
Steering linkage.
*
CARRY OUT the Steering Linkage Component Test. REFER to Steering Linkage Component Test.
*
Steering gear.
*
CARRY OUT the Steering Linkage Component Test. REFER to Steering Linkage Component Test.
Vibration
*
Incorrect wheel alignment.
*
CHECK the wheel alignment and ADJUST if necessary. REFER to: (204-00 )
Specifications (Specifications),
Front Toe Adjustment (General Procedures).
*
Wheels and tires.
*
CHECK the wheels and tires. BALANCE or INSTALL new wheels and tires as necessary.
REFER to: Wheel and Tire (204-04, Removal and Installation).
*
Damaged or worn front wheel bearings.
*
CHECK and INSTALL new wheel hubs as necessary.
REFER to: Wheel Hub (204-01, Removal and Installation).
*
Front strut and spring assemblies.
*
CHECK and INSTALL new suspension components as necessary.
REFER to: Suspension System (204-00, Diagnosis and Testing).
*
Damaged front suspension lower arm(s).
*
CHECK and INSTALL new suspension components as necessary.
REFER to: Suspension System (204-00, Diagnosis and Testing).
*
Steering linkage.
*
CARRY OUT the Steering Linkage Component Test. REFER to Steering Linkage Component Test.
Steering effort is high/low
*
Loose or worn accessory drive belt.
*
CHECK the accessory drive belt. REFER to: (303-05 )
Accessory Drive Belt - 1.6L Duratec-16V (Sigma), Vehicles With: Air Conditioning (Removal and Installation),
Accessory Drive Belt - 1.6L Duratec-16V (Sigma), Vehicles Without: Air Conditioning (Removal and Installation).
*
Power steering hose restriction.
*
CHECK the power steering hoses for damage, kinks or restrictions. INSTALL new components as necessary.
REFER to: Steering Gear to Power Steering Fluid Reservoir Return Line - 1.6L Duratec-16V (Sigma) (211-02, Removal and Installation).
*
Power steering fluid contamination.
*
FLUSH the power steering system.
REFER to: Power Steering System Flushing - 1.6L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT (Sigma) (211-00, General Procedures).
*
Aeration of the power steering fluid.
*
BLEED the power steering system.
REFER to: Power Steering System Bleeding - 1.6L Duratec-16V (Sigma) (211-00, General Procedures).
*
Steering column.
*
CHECK if the floor covering is obstructing the steering gear pinion.
*
CHECK the installation of the floor seal.
*
CARRY OUT the Steering Column Universal Joint Component Test. REFER to Steering Column Universal Joint Component Test.
*
Steering linkage.
*
CARRY OUT the Steering Linkage Component Test. REFER to Steering Linkage Component Test.
*
Steering gear.
*
CARRY OUT the Steering Linkage Component Test. REFER to Steering Linkage Component Test.
*
Worn power steering pump.
*
INSTALL a new power steering pump.
REFER to: Power Steering Pump - 1.6L Duratec-16V (Sigma) (211-02, Removal and Installation).
Excessive noise
*
Power steering operation noise.
*
CARRY OUT the Power Steering Operation Noise Check.
REFER to: Noise, Vibration and Harshness (NVH) (100-04, Diagnosis and Testing).
*
Aeration of the power steering fluid.
*
BLEED the power steering system.
REFER to: Power Steering System Bleeding - 1.6L Duratec-16V (Sigma) (211-00, General Procedures).
*
Power steering lines.
*
CHECK that the power steering line clamps are secure.
REFER to: Steering Gear to Power Steering Fluid Reservoir Return Line - 1.6L Duratec-16V (Sigma) (211-02, Removal and Installation).
*
CHECK the power steering lines for clearance from the vehicle body, front axle crossmember and steering gear.
*
CHECK the steering gear transfer lines for clearance from the steering gear.
*
Steering gear bushings worn or perished.
*
CHECK and INSTALL new components as necessary.
REFER to: Steering Gear Bushing (211-02, Removal and Installation).
*
Loose steering gear retaining bolts.
*
CHECK and INSTALL new bolts as necessary.
REFER to: Specifications (211-02 Power Steering, Specifications).
*
Power steering pump.
*
INSTALL a new power steering pump.
REFER to: Power Steering Pump - 1.6L Duratec-16V (Sigma) (211-02, Removal and Installation).
*
Tie-rod.
*
CARRY OUT the Tie-Rod Component Test. REFER to Tie-Rod Component Test.
Steering does not vary with increased wheel rotation
*
Worn tie-rod ends.
*
INSTALL new components as necessary.
REFER to: Tie-Rod End (211-03, Removal and Installation).
*
Worn front suspension bushings.
*
CHECK and INSTALL new components as necessary.
REFER to: Suspension System (204-00, Diagnosis and Testing).
*
Worn suspension ball joints.
*
CARRY OUT the Ball Joint Inspection Component Test.
REFER to: Suspension System (204-00, Diagnosis and Testing).
*
Steering gear bushings worn or perished.
*
CHECK and INSTALL new components as necessary.
REFER to: Steering Gear Bushing (211-02, Removal and Installation).
*
Loose steering gear retaining bolts.
*
CHECK and INSTALL new bolts as necessary.
REFER to: Specifications (211-02, Specifications).
*
Loose steering column retaining bolts.
*
CHECK and INSTALL new bolts as necessary.
REFER to: Specifications (211-04, Specifications).
*
Loose steering column to steering gear pinion retaining bolt.
*
CHECK and INSTALL a new bolt as necessary.
REFER to: Specifications (211-02, Specifications).
*
Excessive steering gear backlash.
*
CARRY OUT the Steering Linkage Component Test. REFER to Steering Linkage Component Test.
Engine stalls when parking with engine speed at idle
*
Power steering pressure (PSP) switch or circuit.
*
GO to Pinpoint Test A.

PINPOINT TEST A : ENGINE STALLS WHEN PARKING WITH ENGINE SPEED AT IDLE
NOTE:
NOTE:Use a digital multimeter for all electrical measurements.
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
A1: CHECK FOR VOLTAGE TO THE PSP SWITCH
1
Ignition switch in position 0.
2
Disconnect PSP Switch C385.
3
Ignition switch in position II.

4
Measure the voltage between the PSP switch C385 pin 2, circuit 7-CE10 (YE/VT) and the PSP switch C385 pin 1, circuit 9-CE10 (BN/WH) harness side.

Is the voltage greater than 5 volts?
Yes
GO to A2.
No
GO to A3.
A2: CHECK THE PSP SWITCH RETURN CIRCUIT FOR OPEN CIRCUIT OR HIGH RESISTANCE
1
Ignition switch in position 0.
2
Disconnect Powertrain Control Module (PCM) C594.

3
Measure the resistance between the PCM C594 pin F29, circuit 8-CE10 (WH/VT), harness side and the PSP switch C385 pin 3, circuit 8-CE10 (WH/VT), harness side.

Is the resistances less than 5 ohms?
Yes
INSTALL a new PSP switch.
No
REPAIR circuit 8-CE10 (WH/VT).
A3: CHECK THE PSP SWITCH SUPPLY CIRCUIT FOR OPEN CIRCUIT OR HIGH RESISTANCE

1
Ignition switch in position 0.
2
Disconnect PCM C594.
3
Measure the resistance between:
  • the PCM C594 pin F12, circuit 7-CE10 (YE/VT), harness side and the power steering pressure switch 385 pin 2, circuit 7-CE10 (YE/VT), harness side.
  • the PCM C594 pin F10, circuit 9-CE10 (BN/WH), harness side and the PSP switch 385 pin 1, circuit 9-CE10 (BN/WH), harness side.

Is the resistance less than 5 ohms?
Yes
INSTALL a new PCM. REFER to: (418-01 )
Module Configuration (General Procedures),
Programmable Module Installation (General Procedures).
No
REPAIR circuit 7-CE10 (YE/VT) or circuit 9-CE10 (BN/WH).

Components Tests

Steering Linkage

  1. Grasp the steering wheel firmly and move it up and down and to the left and right without turning the steering wheel to check the steering column bearing for wear, steering column shaft for wear, steering wheel for looseness and steering column for looseness. If the steering column bearing or the steering column shaft is worn install a new steering column.
    REFER to: Steering Column (211-04, Removal and Installation).
    If the steering wheel or the steering column is loose, tighten the steering wheel or the steering column retaining bolts.
    REFER to: Specifications (211-04, Specifications).
  1. With the road wheels in the straight ahead position, gently turn the steering wheel to the left and the right to check for free play in the steering linkage.
  1. There should be no excessive free play at the steering wheel rim. If there is excessive free play, CHECK the tie-rod inner and outer ball joints, REFER to Tie-Rod Component Test in this procedure. CHECK the steering column universal joint, REFER to Steering Column Universal Joint Component Test in this procedure. If there is no free play in the tie-rod and the steering column, install a new steering gear.
    REFER to: Steering Gear (211-02, Removal and Installation).

Tie-Rod

CAUTION:
CAUTION:Steering gear boots must be handled carefully to avoid damage. Use new steering boot clamps when installing the steering gear boots.
NOTE:
NOTE:Noises such as knocks, which may appear to originate from the steering linkage, may also be generated by front suspension components.
REFER to: Noise, Vibration and Harshness (NVH) (100-04, Diagnosis and Testing).
  1. Raise and support the vehicle. REFER to: (100-02 Jacking and Lifting)
    Jacking (Description and Operation),
    Lifting (Description and Operation).

  1. Firmly grasp the road wheel and apply a rocking motion checking for any free play in the wheel bearing or suspension components.
  1. CAUTION:
    CAUTION:To prevent damage to the steering linkage, turn the steering wheel to move the steering linkage to the right-hand steering lock stop.
    Turn the steering wheel to position the steering linkage against the right-hand steering lock stop.

  1. NOTE:
    NOTE:To isolate the steering gear design clearance, check the right-hand steering linkage with the steering held against the right-hand steering lock stop.
    With the aid of another technician holding the steering linkage against the right-hand steering lock stop, firmly grasp the road wheel and apply a rocking motion checking for any free play in the steering linkage.

  1. Detach the steering gear boot from the steering gear body and check for free play at the tie-rod inner ball joint.
  1. If there is free play at the tie-rod inner ball joint, install a new tie-rod.
    REFER to: Tie Rod (211-03 Steering Linkage, Removal and Installation).
  1. Check the tie-rod end for free play. Install a new tie-rod end if necessary.
    REFER to: Tie-Rod End (211-03, Removal and Installation).
  1. CAUTION:
    CAUTION:To prevent damage to the steering linkage, turn the steering wheel to move the steering linkage to the left-hand steering lock stop.
    Turn the steering wheel to position the steering linkage against the left-hand steering lock stop.

  1. NOTE:
    NOTE:To isolate the steering gear design clearance, check the left-hand steering linkage with the steering held against the left-hand steering lock stop.
    With the aid of another technician holding the steering against the left-hand steering lock stop, firmly grasp the road wheel and apply a rocking motion checking for any free play in the steering linkage.

  1. Detach the steering gear boot from the steering gear body and check for free play at the tie-rod inner ball joint.
  1. If there is free play at the tie-rod inner ball joint, install a new tie-rod.
    REFER to: Tie Rod (211-03 Steering Linkage, Removal and Installation).
  1. Check the tie-rod end for free play. Install a new tie-rod end if necessary.
    REFER to: Tie-Rod End (211-03, Removal and Installation).

Turning Effort Test

NOTE:
NOTE:Before carrying out this test, make sure that the suspension components are serviceable.
NOTE:
NOTE:Before carrying out this test, make sure that the steering column is serviceable.
NOTE:
NOTE:Before carrying out this test, make sure that the toe adjustment and tire pressures are correct.
  1. Park the vehicle on a dry, even surface and apply the parking brake.
  1. Remove the driver air bag module. REFER to: (501-20B Supplemental Restraint System)
    Driver Air Bag Module (Removal and Installation),
    Driver Air Bag Module (Removal and Installation).
  1. Connect the air bag simulators to the sub-harnesses in place of the driver air bag module at the top of the steering column.
  1. Start the engine and turn the steering wheel from lock to lock several times until the power steering fluid has reached normal operating temperature.
  1. Using a suitable torque wrench and socket, check the steering wheel turning effort.
  1. If the steering wheel turning effort is greater than the specification, install a new steering gear. REFER to:
    Specifications (211-00 Steering System - General Information, Specifications),
    Steering Gear (211-02, Removal and Installation).

Steering Column Universal Joint

  1. WARNING:
    WARNING:Install a new steering column to steering gear pinion retaining bolt. Failure to follow this instruction may result in personal injury.
    Detach the steering column from the steering gear pinion.
    • Discard the steering column to steering gear pinion retaining bolt.

  1. Check for smooth movement of the steering column universal joint.
    1. Hold the steering column universal joint yoke.
    1. Articulate the free yoke in a figure of eight movement.
    • If the movement is not smooth or resistance is felt, install a new steering column.
      REFER to: Steering Column (211-04 Steering Column, Diagnosis and Testing).

  1. Hold both of the steering column universal joint yokes and twist them clockwise and counterclockwise.
    • If movement is felt, install a new steering column.
      REFER to: Steering Column (211-04 Steering Column, Diagnosis and Testing).

Steering System > < 211-00 Steering System - General Information|Specifications