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ZF Power Steering Pump

WARNING: Do not mix oil types. Any mixture or any unapproved oil can lead to seal deterioration and leaks. A leak can ultimately cause loss of fluid, which can result in a loss of power steering assist.
NOTE: This procedure is for motorhome vehicles equipped with either the Hydro-Boost or Hydro-Max brake systems.
  1. Remove the fuel pump fuse to prevent engine starting. See Figure. Fuel pump fuse is in battery junction box, in left rear corner of engine compartment next to master cylinder.
  2. Disconnect the power steering return hose. Plug the reservoir fitting (power steering fluid cooler to power steering oil reservoir).
  3. Attach an extension hose between the power steering return hose and an empty container.
  4. Raise the front wheels off the floor.
  5. Fill the reservoir. Use Motorcraft MERCON® Multi-Purpose ATF XT-2-QDX or equivalent MERCON® fluid.
    6. CAUTION: Do not crank the engine for more than 15 seconds at a time. Allow the starter to cool for 1 minute before cranking again. Premature starter failure can occur.
    CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump could occur.
  6. Turn the steering wheel from stop-to-stop while cranking the engine until the fluid exiting the power steering return hose is clear of all contamination and debris. Add fluid as needed. Use Motorcraft MERCON® Multi-Purpose ATF XT-2-QDX or equivalent MERCON® fluid.
  7. Lower the vehicle.
  8. Disconnect the extension hose from the power steering return hose. See Fig 1. Remove the plug. Attach the power steering return hose to the reservoir.
    Fig 1: Disconnecting Extension Hose
    G00124037Courtesy of FORD MOTOR CO.
  9. Fill the reservoir. Use Motorcraft MERCON® Multi-Purpose ATF XT-2-QDX or equivalent MERCON® fluid.
  10. Install the fuel pump fuse.
    11. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump could occur.
  11. Start the engine and turn the steering wheel from stop-to-stop.
    12. NOTE: If the power steering system is noisy and accompanied by evidence of aerated fluid it will be necessary to purge the power steering system.
  12. Check the power steering fluid level. See Fig 2.
Fig 2: Checking Fluid Level
G00124036Courtesy of FORD MOTOR CO.
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