Dismiss Notice



Register Today It's free! This box will disappear once registered!

2002 4.0L Rack and pinion replacement?

Discussion in 'Stock 2002 - 2005 Explorers' started by jbuszkie, August 21, 2015.

^^Searches ExplorerForum.com^^





  1. jbuszkie

    jbuszkie New Member

    Joined:
    October 23, 2006
    Messages:
    38
    Likes Received:
    0
    Trophy Points:
    6
    City, State:
    Westminster, MA
    Year, Model & Trim Level:
    2002 XLT
    I currently have a leak in my power steering system. It appears to be coming from the high pressure hose where it connects to the rack. It's pretty well rusted. I'm afraid that I'm not going to be able to loosen the nut on the rack that holds the bracket that secures the HP line. I'm afraid I'm just going to snap it off! so.. I bought a new rack just in case.

    I watched this video and one other similar.
    https://www.youtube.com/watch?v=9gv35Qyeu-g

    this was for a older model. My question is.. Is it about the same to remove mine? The Chiltons(or whatever I have) repair manual said something about having to remove the lower control arm? Is that true?

    Any other thoughts or tips to guide me?

    I'm really hoping to just replace the HP line and be done!

    It might be a long weekend!
     
  2. Support EF

    Join the Elite Explorers for $20

    Explorer Forum has probably saved you that much already, and will continue to save you money as you learn how to diagnose fix problems yourself and learn which modifications work without having to experiment on your own. Elite Explorer members see practically no ads, can add their own profile photo, upload photo attachments in all forums, and Media Gallery, create more private Conversations, and more. Join Today. Your support is greatly appreciated.



  3. EXPLORER04

    EXPLORER04 Active Member

    Joined:
    April 8, 2008
    Messages:
    559
    Likes Received:
    5
    Trophy Points:
    18
    City, State:
    Buffalo, NY
    Year, Model & Trim Level:
    04 XLT
  4. jbuszkie

    jbuszkie New Member

    Joined:
    October 23, 2006
    Messages:
    38
    Likes Received:
    0
    Trophy Points:
    6
    City, State:
    Westminster, MA
    Year, Model & Trim Level:
    2002 XLT
    Thanks for that! It's what I was afraid of!

    There's a lot of "Discard the nuts" The new rack certainly didn't come with all those new nuts! How many people actually use new nuts??

    Jim
     
  5. lincolnshibuya

    lincolnshibuya Active Member

    Joined:
    July 1, 2014
    Messages:
    879
    Likes Received:
    61
    Trophy Points:
    38
    City, State:
    kc mo
    Year, Model & Trim Level:
    2002 mercury mountaineer
    just use blue loctite, they have that in the service manual for safety reason. I re-used mine when I did my rack and pinion (got a 4.6 though) I only used new nuts/bolts if they are supplied on the new part.
     
  6. jbuszkie

    jbuszkie New Member

    Joined:
    October 23, 2006
    Messages:
    38
    Likes Received:
    0
    Trophy Points:
    6
    City, State:
    Westminster, MA
    Year, Model & Trim Level:
    2002 XLT
    I couldn't get the hoses of the rack.. They snapped. so now I do have to replace the rack..

    I have the high pressure hose. But the return hose is special. It's metal to a crimped fitting to rubber then to the cooler. All the websites list just a rubber hose for the return line? Where do I get this special return hose?

    Jim
     
  7. jbuszkie

    jbuszkie New Member

    Joined:
    October 23, 2006
    Messages:
    38
    Likes Received:
    0
    Trophy Points:
    6
    City, State:
    Westminster, MA
    Year, Model & Trim Level:
    2002 XLT
    Damn!!!! :fire:

    I couldn't free up the bolt to the lower control arm!! grrr...
    So it looks like I have to pack it up and send it to the mechanic! :(
    I'm so disappointed!
     
    Last edited: August 23, 2015
  8. JoshMcMadMac

    JoshMcMadMac Well-Known Member

    Joined:
    December 20, 2009
    Messages:
    1,052
    Likes Received:
    10
    Trophy Points:
    48
    City, State:
    Waynesboro, PA
    Year, Model & Trim Level:
    2002 Mercury Mountaineer
    I am getting ready to do this job. Does anyone know the total capacity for the power steering system? I need to pick up fluid and would like to have an educated guess as to how much to get.
     
  9. JoshMcMadMac

    JoshMcMadMac Well-Known Member

    Joined:
    December 20, 2009
    Messages:
    1,052
    Likes Received:
    10
    Trophy Points:
    48
    City, State:
    Waynesboro, PA
    Year, Model & Trim Level:
    2002 Mercury Mountaineer
    My new rack had at least some fluid in it, but the system took almost a full quart on top of that. I would pick up two quarts just to be safe, and remember that it takes Mercon V ATF, not regular power steering fluid.

    For my 2WD I did not have to remove the control arms. The tie-rod ends came off with some Kroil sprayed on them and a 2lb hammer massage. They would not budge off of the rack though, and my undercarriage is in pretty good shape. I would definitely plan on replacing them, and just return the new ones if you get lucky reusing the old ones. Also, the rack bushings were not included with the new rack so I had to reuse the old ones. I got creative with a ball joint press to get them out, but that could have been an unpleasant "gotcha" if I was not prepared.
     

Share This Page







We Support Our Troops!