Installed the pump and found it leaked at the HP line flare nut going into the pump. When I installed the seal that came with the pump on this flare nut, it looked too big.
After some digging, discovered correct seal is smaller than what came with the pump. Ford has made these in several different sizes, this part number is correct one for this application, 388898-S, 13 mm. I found no reference to this part number in ALLDATA
Made up this installation tool to put the seal over the flare nut threads without damage:
One upgrade I made was to discard the wiring bracket and cut off the stud protrusions on the mounting bolts, then put some wire wrap on the wiring running down the left side of the head and block. Cleaner install and now the wiring doesn't contact other parts like the exhaust manifold or steering shaft boot:
No leaks, works great now. Although Ford procedures in ALLDATA call for pulley removal, I can advise it is not necessary and a real pain to do this, as access is very limited even when moving the reservoir out of the way. The only tool I found to tighten the 18mm flare nut was a flare crows foot on several extensions.
Here's what I suggest for this job:
Removal
- Remove oil filter
- Drain reservoir of PS fluid and remove feed line from reservoir into pump
- Loosen 18mm HP flare nut with crows foot
- Remove 10 mm nut holding HP line to frame
- Remove bracket and bolts holding the PS Pump in place
- Drop pump with pulley out the bottom and remove HP line fitting from pump
Install
- Finger tighten 18mm flare nut HP line to pump
- Install pump to engine from bottom. Be careful to use correct torque on these bolts, 15 ft-lbs. These will easily strip out the threaded aluminum bosses on the head or timing chain cover
- Tighten 18mm flare nut HP line to pump with crows foot on extension
- Install and tighten 10 mm nut to hold HP line to frame
- Install feed line from reservoir into pump. I double clamped this to make sure it doesn't leak
- Replace oil filter
- Fill reservoir with correct fluid, I used Mercon V
- Pull vacuum on the reservoir to remove air from the system, fill reservoir as necessary
- Start engine move steering wheel back and forth, make sure reservoir stays full. Top off as necessary