Steering System

211-00-1 Steering System 211-00-1
DESCRIPTION AND OPERATION

Steering System The power steering system transfers driver inputs at
the steering wheel to the front wheels of the
The steering system consists of the following
vehicle. The steering column, hydraulic system and
components:
linkages that transfer these driver inputs make up
• Power steering pump the steering system. Gearing and hydraulic assist
• Steering gear are used to significantly reduce steering efforts.
• Power steering lines For information on the power steering pump,
steering gear, power steering lines, fluid reservoir
• Fluid reservoir and fluid cooler, refer to Section 211-02.
• Fluid cooler For information on the steering linkage, refer to
• Steering linkage Section 211-03.
• Steering wheel For information on the steering wheel and steering
• Steering column column, refer to Section 211-04.
• Steering column shaft For information on the steering column switches,
refer to Section 211-05.
• Steering column switches
Copyright  2007, Ford Motor Company

Last updated: 3/16/2007 2008 F-250, 350, 450, 550 Super Duty, 7/2007
DIAGNOSIS AND TESTING

Steering System Special Tool(s)
Vehicle Communication Module
Special Tool(s) (VCM) and Integrated
Diagnostic System (IDS)
100W/12 Volt DC UV Lamp software with appropriate
164-R0751 hardware, or equivalent scan
tool
Material
Dial Thermometer 0-220°F Item Specification

023-R0007 or equivalent Dye-Lite ATF/Power —
Steering Fluid Leak
Detection Dye
164-R3701 (Rotunda)
MERCON V Automatic MERCON V
Transmission Fluid
XT-5-QM (or XT-5-QMC)
Evacuation Cap, Power Steering (US); CXT-5-LM12
211-265 or equivalent (Canada)
Principles of Operation
Power Steering
The power steering system uses a vane-type pump
to move the fluid from the reservoir to the steering
Power Steering Adapters gear and through the rest of the steering hydraulic
211-D019 (D89P-33610-A) system. The power steering pump is mounted to the
engine and driven by the engine accessory drive
belt. Power steering fluid is pulled into the pump
from the reservoir. The power steering fluid is
trapped between the pump vanes and moved to the
high pressure side of the pump creating a flow of
Power Steering Analyzer Kit fluid. The restriction of this flow by the steering
211-D001 (014-00207) or gear creates the pressure that provides the steering
equivalent assist. A combined pressure relief/flow valve is built
into the pump to control the maximum pressure and
flow provided to the steering system. This action
prevents damage to the system and provides the
correct level of assist during all engine speeds.
Vacuum Pump Kit While under pressure, the power steering fluid flows
416-D002 (D95L-7559-A) or through the high pressure power steering line to the
equivalent steering gear. The fluid exits the gear and flows
through the return line, cooler and finally to the
reservoir. The reservoir slows the fluid, allows air to
escape and filters the fluid before returning it to the
pump.
(Continued)
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of
mechanical damage.

DIAGNOSIS AND TESTING (Continued)
Visual Inspection Chart • If a leak is detected at a constant tension
Mechanical spring clamp, verify that the hose is not
damaged and fully installed on the hose
• Fluid level
• Tire pressure fitting. Make sure that the constant tension
• Tires spring clamp is positioned 2 mm (0.078 in)
• Drive belt from the end of the hose. If the leak
• Drive belt tensioner remains, install a new constant tension spring
• Steering column alignment clamp.
• Tie-rod ends
• Suspension components • If a leak is detected at a screw clamp joint,
• Steering column shaft U-joints verify that the hose is fully installed on the
• Intermediate shaft bolts hose fitting and the clamp is positioned 2 mm
• Power steering pressure lines, fittings or O-rings (0.078 in) from the end of the hose before
• Power steering return hoses and clamps
• Steering gear tightening the screw clamp. If the leak
• Power steering pump remains, install a new screw clamp. Refer to
Section 211-02.
3. Inspect the power steering fluid for the 6. Visually inspect the power steering components
following conditions: for leaks.
• Aeration or foam: Purge the power steering • If a leak is detected in the power steering
system. Refer to Power Steering System pressure line or return hose, install a new
Purging in this section. hose. Refer to Section 211-02.
• Overheating or contamination: Flush the • If a leak is detected in the power steering
power steering system. Refer to Power pump, install a new power steering pump.
Steering System Flushing in this section. Refer to Section 211-02.
4. NOTE: It may be necessary to add power • If a leak is detected at the steering gear,
steering fluid to achieve the correct level. inspect the steering gear and determine the
Check the fluid level and clean the power source of the leak. If the leak is related to
steering components. seals, O-rings and/or the sector shaft cover,
reseal the steering gear. Refer to Disassembly
With the ignition OFF: and Assembly in Section 211-02. If there is
• Check the power steering fluid level and damage to the steering gear housing or
add fluid as necessary. mating components, a new steering gear must
• Wipe off any visible signs of fluid or be installed. Refer to Section 211-02.
residue build up. • If a leak is detected in the power steering
• NOTICE: Do not hold the steering wheel reservoir, install a new reservoir. Refer to
at the stops for an extended amount of Section 211-02.
time. Damage to the power steering pump 7. For information on power steering leak
can occur. detection, refer to Component Tests in this
Start the engine and turn the steering wheel section.
from stop-to-stop several times. 8. If an obvious cause for an observed or reported
5. Visually inspect the power steering hydraulic concern is found, correct the cause (if possible)
line/hose connections for leaks. before proceeding.
9. If the cause is not visually evident, verify the
• If a leak is detected at a threaded fitting,
symptom and GO to Symptom Chart —
tighten to specification. If the leak is still
Steering System or GO to Symptom Chart —
evident, visually inspect the O-rings or
NVH.
Teflon seals. Install new O-rings or
Teflon seals as necessary. Refer to Section
211-02.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Steering System Symptom Definitions Lack of Assist or Inconsistent Assist
Lack of assist or inconsistent assist is experienced
Drift/Pull
when the steering wheel effort is higher than
Pull is described as a tugging sensation felt by the
normal. Hard steering can remain constant through
hands on the steering wheel that must be overcome
the full turn or occur near the end of a turn. It is
to keep the vehicle going straight.
important to know the difference between hard
Drift describes what a vehicle with this condition steering/lack of assist and poor returnability/sticky
does with the hands off the steering wheel. steering.
• A vehicle-related drift/pull on a flat road can Hard steering or lack of assist can result from either
cause a consistent deviation from the hydraulic or mechanical conditions. It is extremely
straight-ahead path and require constant steering important to know if this concern occurs during
input in the opposite direction to counteract the driving or during high-effort parking maneuvers.
effect.
Poor Returnability/Sticky Steering
• Drift/pull can be induced by conditions external to Poor returnability and sticky steering is used to
the vehicle, such as wind or road camber. describe the poor return of the steering wheel to
Excessive Steering Wheel Play center after a turn or steering correction is
Excessive steering wheel play is a condition in completed.
which there is too much steering wheel movement Wander
before the wheels move. A small amount of steering Wander is the tendency of the vehicle to require
wheel free play is considered normal. frequent, random left and right steering wheel
corrections to maintain a straight path down a level
road.
Symptom Chart — Steering System
Symptom Chart — Steering System

Condition Possible Sources Action
• Steering has lack of assist or • Steering gear • GO to Pinpoint Test A.
inconsistent assist — vehicles • Power steering pump
with vacuum boost • Restricted power steering
lines/hoses
• Steering has lack of assist or • Steering gear • GO to Pinpoint Test B.
inconsistent assist — vehicles • Power steering pump
with Hydro-Boost • Restricted power steering
lines/hoses
• Excessive steering wheel play • Steering gear meshload • GO to Pinpoint Test C.
• Steering linkage
• Steering column shaft
• Steering system • Steering column • GO to Pinpoint Test D.
drift/pull/wander shaft/U-joints
• Steering gear
• Steering gear mounts
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Symptom Chart — Steering System (Continued)
• Poor returnability/sticky • Binding steering column • INSTALL a new steering
steering shaft/coupling U-joints column shaft. REFER to
Section 211-04.
• Loose, worn or damaged • GO to Steering Linkage
steering linkage Component Test in this
section.
• Binding suspension • To continue the suspension
components diagnosis, REFER to Section
204-00.
• Binding steering column • INSTALL a new steering
bearing(s) column. REFER to Section
211-04.
• Binding dash boot seal • INSTALL a new dash boot
seal. REFER to Section
211-04.
• Steering gear • REPAIR or INSTALL a new
steering gear as necessary.
REFER to Section 211-02.
Symptom Chart — NVH
Symptom Chart — NVH

NOTE: NVH symptoms should be identified using the diagnostic tools that are
available. For a list of these tools, an explanation of their uses and a glossary of
common terms, refer to Section 100-04. Since it is possible any one of multiple
systems may be the cause of a symptom, it may be necessary to use a process of
elimination type of diagnostic approach to pinpoint the responsible system. If this is not
the causal system for the symptom, refer back to Section 100-04 for the next likely
system and continue diagnosis.
• Steering system cold start • Blockage in the power • NOTE: Some noise during
noise steering fluid reservoir caused an extremely cold start
by power steering fluid (-12.2°C [-10°F]) is normal
contamination and should improve as the
steering system warms up
(usually within 60 seconds).
NOTE: It may be necessary
to remove the power steering
fluid reservoir to flush
contamination trapped in the
reservoir screen.
CHECK the power steering
fluid reservoir for
contamination. FLUSH the
power steering system as
necessary. REFER to Power
Steering System Flushing in
this section.
• Air in the steering hydraulic • CHECK for leaks in the
system (aerated fluid) system. REFER to Power
Steering Leak Test
Component Test. PURGE the
air from the system. REFER
to Power Steering System
Purging in this section.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Symptom Chart — NVH (Continued)
• Steering grunt or shudder — • Air in the steering hydraulic • CHECK for leaks in the
occurs when turning into or system (aerated fluid) system. REFER to Power
out of a turn at low speeds Steering Leak Test
(temperature sensitive) Component Test. PURGE the
• Steering gear or power • GO to Steering Gear
steering hoses Grunt/Shudder Component
Test in this section.
• Steering system clonk — • Air in the steering hydraulic • NOTE: Some amount of
hydraulic knocking sound system (aerated fluid) clonk noise is considered
acceptable. If in doubt of the
acceptability, compare to
another vehicle.
CHECK for leaks in the
system. REFER to Power
Steering Leak Test
• Power steering pump moan • Low fluid • CHECK the fluid level. FILL
— loud humming noise as necessary. REFER to
occurs when the steering Power Steering System
wheel is rotated to the stop Filling in this section.
position. Produces a 120-600
Hz frequency that changes
with rpm
• Air in the steering hydraulic • CHECK for leaks in the
system (aerated fluid) system. REFER to Power
Steering Leak Test
Purging in this section. If a
pump moan still exists,
INSTALL a new power
steering pump. REFER to
Section 211-02.
• Power steering fluid reservoir • REMOVE the reservoir.
or screen is blocked or REFER to Section 211-02.
damaged FLUSH or INSTALL a new
reservoir as necessary.
• Power steering line/hose • INSPECT the power steering
grounded to chassis lines/hoses. REPAIR as
necessary.
• Power steering pump brackets • CHECK bolts, brackets and
loose or misaligned bracket alignment. TIGHTEN
bolts to specification.
REPAIR or INSTALL new
brackets as necessary. REFER
to Section 211-02.
• Steering gear isolators • INSPECT the isolators for
wear or damage. REPAIR as
necessary.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

• Steering gear clunk — occurs • Steering gear • INSPECT the steering gear
only while cornering over a for loose mounting bolts.
bump (can be temperature TIGHTEN to specification as
sensitive) necessary. REFER to Section
211-02.
• Feedback (rattle, chuckle or • Steering column • INSTALL a new steering
knocking noise in the steering shaft/coupling joints damaged column shaft. REFER to
gear) — roughness is felt in or worn Section 211-04.
the steering wheel when the
vehicle is driven over rough
surfaces
• Loose, damaged or worn • INSPECT and INSTALL new
tie-rod ends tie-rod ends as necessary. GO
to Steering Linkage
Component Test in this
section.
• Steering gear mounting bolts • TIGHTEN the bolts to
loose specification or INSTALL
new bolts as necessary.
• Steering column • TIGHTEN the bolts to
shaft/coupling bolts are loose specification. REFER to
Section 211-04.
• Steering column damaged or • REPAIR or INSTALL a new
worn steering column as necessary.
• Accessory drive belt • Engine accessory drive • REFER to Section 303-00 to
squeal/chirp — when rotating system continue accessory drive
the steering wheel from system diagnosis.
stop-to-stop
• Power steering hiss or whistle • Steering column • REPAIR or INSTALL a new
shaft/coupling-to-steering gear steering column shaft as
is binding or misaligned necessary. REFER to Section
211-04.
• Grounded or loose steering • REPAIR as necessary.
column boot at the dash panel
• Damaged or worn steering • INSTALL a new steering
gear input shaft and valve gear as necessary. REFER to
Section 211-02.
• Restricted power steering • GO to Pinpoint Test A.
lines/hoses
• Steering column rattle • Loose bolts or attaching • TIGHTEN the bolts to
brackets specification.
• Loose, worn or insufficiently • LUBRICATE bearings or
lubricated column bearings INSTALL new steering
column bearings or steering
column as necessary. REFER
to Section 211-04.
• Steering shaft insulators • INSTALL new insulators.
damaged or worn REFER to Section 211-04.
• Steering column • INSPECT the rubber spider
shaft/coupling compressed or coupling for damage.
extended INSTALL a new steering
column shaft. REFER to
Section 211-04.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

• Steering gear squeak • Incorrect power steering fluid • If incorrect power steering
in system fluid is suspected, FLUSH the
power steering system.
REFER to Power Steering
System Flushing. If noise
persists after system flush,
INSTALL new steering gear
seals as necessary. REFER
to Disassembly and Assembly
in Section 211-02.
• Steering gear seals • NOTE: Use the chassis ears
to verify that the steering gear
is the source of the noise. It
may be necessary to replicate
the customer operating
conditions (fluid temperature,
turning rate of steering wheel)
to get the squeak to reoccur.
INSTALL new steering gear
seals as necessary. REFER to
Disassembly and Assembly in
Section 211-02.
• Stone shield (if equipped) • Make sure that the stone
shield is correctly installed
and that it is not making
contact with the steering
shaft. REPOSITION stone
shield or INSTALL a new
stone shield as necessary.
• Steering column squeak, • Insufficiently lubricated • LUBRICATE the steering
cracks or grinds steering shaft bushings shaft and shaft tube seals.
• Loose or misaligned steering • TIGHTEN or ALIGN the
column shrouds steering column shrouds.
• Steering wheel rubbing • REPOSITION the steering
against steering column column shrouds.
shrouds
• Upper or lower bearing • REPOSITION the bearing
sleeves out of position sleeves.
• Power steering pump noisy • Power steering pump • INSTALL a new power
steering pump as necessary.
• Power steering pump relief • Power steering fluid flow into • Acceptable condition.
noise the bypass valve of the pump
valve housing, with fluid
temperature below 54°C
(130°F)
• Power steering pump whine • Aerated fluid • CHECK for a leak in the
noise system. REFER to Power
Steering Fluid Leak Test
Purging.
• Damaged power steering • INSTALL a new power
pump steering pump as necessary.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

• High speed shake or shimmy • Worn or damaged steering • GO to Steering Linkage
linkage components Component Test in this
section.
Pinpoint Tests This pinpoint test is intended to diagnose

the following:
Pinpoint Test A: Steering Has Lack of Assist
or Inconsistent Assist — Vehicles with • Steering gear
Vacuum Boost • Power steering pump
Normal Operation • Power steering hoses
Hard steering or lack of assist is experienced when
the steering wheel effort exceeds specifications.
Hard steering can remain constant through the full
turn, occur near the end of a turn or differ right to
left. It is important to know the difference between
hard steering/lack of assist and poor
returnability/sticky steering.
PINPOINT TEST A: STEERING HAS LACK OF ASSIST OR INCONSISTENT ASSIST — VEHICLES WITH
VACUUM BOOST
Test Step Result / Action to Take
A1 CHECK THE STEERING ASSIST WITH THE ENGINE RPM
RAISED
• NOTICE: Do not hold the steering wheel at the stops for an

extended amount of time. Damage to the power steering Yes
pump can occur. INSTALL a new power steering pump.
Set the engine at 2,100 rpm and turn the steering wheel fully to REFER to Section 211-02.
the left and right. No
• Is steering assist normal with the engine rpm raised? GO to A2.
A2 CHECK FOR A CHANGE OF ASSIST ON LEFT AND RIGHT
TURNS
• With the engine at idle, turn the steering wheel fully to the left Yes
and to the right. INSTALL a new steering gear. REFER to
• Does the steering assist change when turning from right to Section 211-02.
left? No
GO to A3.
A3 CHECK THE STEERING LINES AND HOSES FOR
RESTRICTIONS
• Inspect the steering lines and hoses for damage, kinks or Yes
restrictions. INSTALL new lines or hoses as
• Are the steering lines or hoses damaged, kinked or necessary.
restricted? No
GO to A4.
A4 MONITOR THE ENGINE RPM CHANGES
NOTICE: Do not hold the steering wheel at the stops for an
extended amount of time. Damage to the power steering pump
can occur.
NOTE: Make sure that the vehicle is on a flat, dry surface, all
accessories are in the OFF position and that the steering system is
at normal operating temperature.
• Connect the scan tool.
• Start the engine.
• With the engine at idle, raise the power steering fluid
temperature to 74-80°C (165-176°F) by rotating the steering
wheel fully to the left and right several times.
(Continued)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

PINPOINT TEST A: STEERING HAS LACK OF ASSIST OR INCONSISTENT ASSIST — VEHICLES WITH
VACUUM BOOST (Continued)
A4 MONITOR THE ENGINE RPM CHANGES (Continued)
• Enter the following diagnostic mode on the scan tool:
DataLogger — PCM.
• While monitoring the engine revolutions per minute (RPM) PID, Yes
turn the steering wheel quickly to the left stop position and then INSTALL a new steering gear. REFER to
to the right stop position. Section 211-02.
• Note the RPM PID during the turns. No
• Does the PID change (even temporarily) more than 30 rpm INSTALL a new power steering pump.
when turning the steering wheel? REFER to Section 211-02.
Pinpoint Test B: Steering Has Lack of Assist This pinpoint test is intended to diagnose
or Inconsistent Assist — Vehicles With the following:
Hydro-Boost • Steering gear
Normal Operation • Power steering pump
Hard steering or lack of assist is experienced when • Power steering hoses
the steering wheel effort exceeds specifications.
Hard steering can remain constant through the full
turn, occur near the end of a turn or differ right to
left. It is important to know the difference between
hard steering/lack of assist and poor
returnability/sticky steering.
PINPOINT TEST B: STEERING HAS LACK OF ASSIST OR INCONSISTENT ASSIST — VEHICLES WITH
HYDRO-BOOST
B1 CHECK THE STEERING ASSIST WITH THE ENGINE RPM
RAISED
• NOTICE: Do not hold the steering wheel at the stops for an

extended amount of time. Damage to the power steering Yes
pump can occur. INSTALL a new power steering pump.
Set the engine at 2,100 rpm and turn the steering wheel fully to REFER to Section 211-02.
the left and right. No
• Is steering assist normal with the engine rpm raised? GO to B2.
B2 CHECK FOR A CHANGE OF ASSIST ON LEFT AND RIGHT
TURNS
• With the engine at idle, turn the steering wheel fully to the left Yes
and to the right. INSTALL a new steering gear. REFER to
• Does the steering assist change when turning from right to Section 211-02.
left? No
CARRY OUT the Pump Flow and
Pressure Component Test in this section.
Pinpoint Test C: Excessive Steering Wheel

Play
This pinpoint test is intended to diagnose
the following:
• Steering linkage
• Steering column shaft
• Steering gear meshload
2008 F-250, 350, 450, 550 Super Duty, 7/2007

PINPOINT TEST C: EXCESSIVE STEERING WHEEL PLAY
C1 CHECK THE STEERING LINKAGE
• Carry out the Steering Linkage Component Test in this section. Yes
• Is the steering linkage OK? GO to C2.
No
INSTALL new steering linkage
components as necessary. REFER to
Section 211-03.
C2 CHECK THE STEERING COLUMN SHAFT
• Inspect the steering column shaft U-joints and fasteners for Yes
looseness. CHECK and ADJUST the steering gear
• Are the U-joints and fasteners OK? meshload as necessary. Refer to Steering
Gear Meshload Adjustment — F250, F350
in this section.
No
TIGHTEN the steering column shaft
fasteners or INSTALL a new steering
column shaft. REFER to Section 211-04.
Pinpoint Test D: Steering System the following:

Drift/Pull/Wander • Steering column shaft
This pinpoint test is intended to diagnose • Steering gear
• Steering gear mounts
• Steering column shaft U-joints
PINPOINT TEST D: STEERING SYSTEM DRIFT/PULL/WANDER
D1 CHECK THE STEERING COLUMN SHAFT
• NOTE: Be sure to keep the clockspring centered when
disconnecting the intermediate shaft. Refer to Section 501-20B. Yes
Check the steering column and shaft for grounding. GO to D2.
• Disconnect the steering column shaft at the steering column. No
• Inspect the steering column shaft U-joints for looseness or wear. INSTALL new steering column shaft as
• Are the steering column shaft U-joints OK? necessary. REFER to Section 211-04.
D2 CHECK THE STEERING GEAR MOUNTING
• Check the steering gear mounts for looseness or wear. Yes
• Are the steering gear mounts OK? GO to D3.
No
INSTALL a new steering gear as
necessary. REFER to Section 211-02.
D3 CHECK THE STEERING GEAR
• Carry out the Steering Gear Valve Component Test in this Yes
section. REFER to Section 204-00 to diagnose
• Is the steering gear valve OK? suspension system drift/pull/wander.
No
INSTALL a new steering gear as
necessary. REFER to Section 211-02.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Component Tests 11. Stop the engine and inspect the system for
traces of UV dye using the 100W/12 Volt DC
Power Steering Fluid Leak Test UV Lamp. Repair as necessary.
NOTE: This test should only be carried out if a
leak in the system has not been detected during a Pump Flow and Pressure Test — Vehicles
thorough visual inspection. Refer to Inspection and With Hydro-Boost
Verification in this section. WARNING: Do not touch the flowmeter
1. Remove the power steering pump reservoir cap during the test procedure or for several minutes
and check the power steering fluid level. If after use. The flowmeter may become hot during
necessary, add the specified power steering use and can burn unprotected skin. Failure to
fluid. follow this instruction may result in serious
personal injury.
2. Tightly install the Power Steering Evacuation
Cap onto the reservoir and connect the Vacuum NOTE: For power steering pump flow, pressure and
Pump Kit to the Evacuation Cap. relief pressure specifications, refer to General
Specifications/Power Steering Pump in this section.
3. Using the Vacuum Pump Kit, apply 68-85 kPa
(20-25 in-Hg) of vacuum to the power steering 1. NOTICE: Make sure that the connection
system. point will not interfere with any of the
engine accessory drive components or drive
4. Observe the vacuum gauge for 30 seconds. If
belts. Damage to the analyzer or accessory
the vacuum gauge reading drops more than 3
drive components can occur.
kPa (0.88 in-Hg), a leak is present.
Install the Power Steering Adapters and the
5. Remove the Vacuum Pump Kit.
Power Steering Analyzer Kit between the
6. Start the engine and insert the Dial pressure line and the pressure inlet port of the
Thermometer into the Evacuation Cap. Hydro-Boost brake booster. Make sure the
7. NOTICE: Do not hold the steering wheel at power steering analyzer gate valve is fully
the stops for an extended amount of time. open.
Damage to the power steering pump may 2. Place a Dial Thermometer in the power steering
occur. pump reservoir.
With the engine at idle, raise the power steering 3. Check the power steering fluid level. If
fluid temperature to 74-80°C (165-176°F) by necessary, add specified power steering fluid.
rotating the steering wheel fully to the left and 4. Install a digital tachometer.
right several times.
5. NOTICE: Do not hold the steering wheel
8. Stop the engine and visually inspect the system against the stops for an extended amount of
for leaks. time. Damage to the power steering pump
• If a leak is evident, repair as necessary. can occur.
• If a leak is not evident, add the specified Start the engine. Place the transmission in
UV fluorescent tracer dye to the power NEUTRAL. Set the parking brake. Raise the
steering fluid. Use 14.78 ml (1/2 oz) of dye power steering fluid temperature to 74-80°C
solution for every 1.89L (2 qt) of power (165-175°F) by rotating the steering wheel fully
steering fluid. to the left and right several times.
9. Start the engine. 6. With the steering wheel in the straight-ahead
10. NOTICE: Do not hold the steering wheel at position, set the engine at idle. Record the flow
the stops for an extended amount of time. rate and pressure readings.
Damage to the power steering pump may • If the flow rate is below the flow rate
occur. specification, check the power steering
With the engine at idle, raise the power steering pump-to-brake booster pressure line for
fluid temperature to 74-80°C (165-176°F) by kinks and restrictions.
rotating the steering wheel fully to the left and
right several times.
2008 F-250, 350, 450, 550 Super Duty, 7/2007
• If the pressure reading is above the pressure 11. Have an assistant turn the steering wheel
specification, check all other power steering slightly in both directions and release quickly
hoses and the fluid cooler for restrictions. while watching the pressure gauge.
7. Partially close the gate valve to obtain 750 psi. • The pressure reading should move from the
Set the engine speed at idle. Record the flow normal back pressure reading and snap back
rate. as the steering wheel is released.
• If the flow is less than the specified flow • If the pressure returns slowly or sticks, the
rate, install a new power steering pump. rotary valve in the steering gear is sticking
8. NOTICE: Do not allow the gate valve to or the steering column is binding. Check the
remain closed for more than 5 seconds. steering column and linkages before
repairing the steering gear.
Completely close and partially open the gate
valve 3 times. Record the pressure relief valve Steering Gear Valve Test
actuation pressure reading. 1. With the vehicle in NEUTRAL, position it on a
• If the pressure does not meet the relief hoist. Refer to Section 100-02.
pressure specification, then install a new • Raise the vehicle until the front wheels are
power steering pump. off the ground.
9. Fully open the gate valve. While reading the 2. NOTE: Do not hold the steering wheel while
pressure gauge, have an assistant gradually carrying out this step.
apply the brake pedal until the relief pressure is
reached and then release the brake pedal Start the engine.
(pressure should quickly build and release). • If the steering wheel rotates in either
Have the assistant gradually apply the brake direction (with no hand input), install a new
pedal again to verify consistency. steering gear. Refer to Section 211-02.
• If the relief pressure can not be reached Steering Gear Grunt/Shudder Test
(brake pedal should be hard), install a new
Hydro-Boost brake booster. Refer to 1. Start and run the vehicle to operating
Section 206-07. temperature.
• If the pressure returns slowly or sticks, 2. Set engine idle speed to 1,200 rpm.
check the brake pedal and bracket for 3. NOTICE: Do not hold the steering wheel
sticking or binding. If the brake pedal and against the stops for an extended amount of
bracket are OK, install a new Hydro-Boost time. Damage to the power steering pump
brake booster. Refer to Section 206-07. will occur.
10. NOTICE: Do not hold the steering wheel Rotate the steering wheel to the RH stop, then
against the stops for an extended amount of turn the steering wheel 90 degrees back from
time. Damage to the power steering pump that position. Slowly turn the steering wheel
can occur. back and forth approximately one-twelfth of a
Have an assistant turn the steering wheel to the full turn.
left and right stops. Record flow rate and 4. Turn the steering wheel another 90 degrees.
pressure readings at the stops. Slowly turn the steering wheel back and forth
• The pressure reading at both stops should be approximately one-twelfth of a full turn.
nearly the same as the pump relief pressure. 5. Repeat the test with the power steering fluid at
• The flow rate should drop below 1.9L/min different temperatures.
(0.5 gal/min). 6. If a light grunt is heard or a low (50-200 Hz)
• If the pressure does not reach the pump shudder is present, this is a normal steering
relief pressure or the flow rate does not drop system condition.
below the specified value, excessive internal
leakage is occurring. Install a new steering
gear as necessary. Refer to Section 211-02.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

7. If a loud grunt is heard, or a strong shudder is
felt, purge the power steering system. Refer to
Power Steering System Purging in this section.
If a loud grunt or strong shudder still exists,
check the power steering lines/hoses for
restrictions or damage and repair as necessary.
Refer to Section 211-02. If the lines/hoses are
OK, install a new steering gear. Refer to
Section 211-02.
Steering Linkage Inspection
Vertical Inspection
NOTE: Checking the steering linkage components 5. Grasp the steering linkage component forging
for vertical (up and down) deflection is preferred, near the ball stud, push upward, pull downward,
however it may be necessary to check some steering and then release it. This will allow the steering
linkage components for lateral (side-to-side) linkage component to be in a relaxed position
deflection due to lack of clearance for the dial when measuring.
indicator. Outer tie-rod ends should always be 6. Zero the dial indicator.
checked for vertical deflection. Using a vice grip 7. NOTE: Make sure that the steering linkage
style, flexible arm Dial Indicator (such as Snap component does not roll during inspection or an
On stock # GA3634) is suggested. inaccurate measurement may occur.
NOTE: The steering linkage component ball studs Using a suitable prying device (approximately
are spring loaded and will normally have a small 457 mm [18 in] long), pry on the steering
amount of vertical deflection when the spring is linkage component forging while observing the
compressed. However, excessive vertical deflection deflection of the dial indicator pointer.
of the studs relative to the sockets may indicate
• Only apply moderate force. Do not move
excessive wear.
the vehicle suspension.
1. Turn the steering wheel to the straight-ahead
8. If the vertical deflection exceeds 2.30 mm (0.09
position and turn the ignition switch to the OFF
in), install a steering linkage component. Refer
position.
to Section 211-03.
2. With the vehicle in NEUTRAL, position it on a
hoist. Refer to Section 100-02. Lateral Inspection
3. NOTE: To obtain the necessary clearance to NOTE: Checking the steering linkage components
install the dial indicator, it may be necessary to for vertical (up and down) deflection is preferred,
remove the wheel and tire. however it may be necessary to check some steering
If necessary, remove the wheel and tire. Refer linkage components for lateral (side-to-side)
to Section 204-04. deflection due to lack of clearance for the dial
indicator. Outer tie-rod ends should always be
4. NOTE: Typical steering linkage shown. checked for vertical deflection. Using a vice grip
Install the dial indicator as shown. style, flexible arm dial indicator (such as Snap On
1 Attach the vise grip/flexible arm to the nut stock # GA3634) is suggested.
of the steering linkage component being 1. Turn the steering wheel to the straight-ahead
tested or the component that the steering position and turn the ignition switch to the OFF
linkage ball stud seats into. position.
2 Position the flexible arm so that the dial 2. With the vehicle in NEUTRAL, position it on a
indicator is positioned on the center of the hoist. Refer to Section 100-02.
steering linkage component cap and lock the
flexible arm.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

3. NOTE: Typical steering linkage shown.
Install the dial indicator.
1 Attach the vise grip/flexible arm to the nut
of the steering linkage component being
tested or the component that the steering
linkage ball stud seats into.
2 Position the flexible arm so that the dial
indicator is positioned on the end of
steering linkage housing and lock the
flexible arm.
4. Have an assistant grasp the tire and move the

steering linkage from side-to-side. Observe and
record the deflection measured with the dial
indicator.
5. If the lateral deflection exceeds 1.30 mm (0.05
in), install a new steering linkage component.
Refer to Section 211-03.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

GENERAL PROCEDURES
Power Steering System Filling
Special Tool(s)
Evacuation Cap, Power Steering
211-265
Fill Adapter Manifold, Power

Steering
211-327
Vacuum Pump Kit

416-D002 (D95L-7559-A) or
equivalent
Material
Item Specification
Transmission Fluid
(US); CXT-5-LM12
(Canada)

GENERAL PROCEDURES (Continued)
Item Description 3. NOTE: The Power Steering Fill Adapter

1 Power steering fluid reservoir Manifold control valves are in the OPEN
2 Control valve (vacuum side) position when the points of the handles face the
center of the Power Steering Fill Adapter
3 Control valve (fluid container side)
Manifold.
4 Fluid container
Close the Power Steering Fill Adapter Manifold
control valve (fluid side).
1. NOTICE: If the air is not purged from the 4. Open the Power Steering Fill Adapter Manifold
power steering system correctly, premature control valve (vacuum side).
power steering pump failure may result. The
condition can occur on pre-delivery vehicles 5. Using the Vacuum Pump Kit, apply 68-85 kPa
with evidence of aerated fluid or on vehicles (20-25 in-Hg) of vacuum to the power steering
that have had steering component repairs. system.
Remove the power steering fluid reservoir cap.
6. Observe the Vacuum Pump Kit gauge for 30
2. Install the Power Steering Evacuation Cap, seconds.
Power Steering Fill Adapter Manifold and
Vacuum Pump Kit as shown in the illustration. 7. If the Vacuum Pump Kit gauge reading drops
more than 3 kPa (0.88 in-Hg), correct any leaks
in the power steering system or the Power
Steering Evacuation Cap, Power Steering Fill
Adapter Manifold and Vacuum Pump Kit
before proceeding.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

8. NOTE: The Vacuum Pump Kit gauge reading 13. Remove the Power Steering Evacuation Cap,
will drop slightly during this step. Power Steering Fill Adapter Manifold and
Slowly open the Power Steering Fill Adapter Vacuum Pump Kit.
Manifold control valve (fluid side) until power
steering fluid completely fills the hose and then 14. Install the reservoir cap.
close the control valve.
15. NOTICE: Do not hold the steering wheel
9. Using the Vacuum Pump Kit, apply 68-85 kPa against the stops for an extended amount of
(20-25 in-Hg) of vacuum to the power steering time. Damage to the power steering pump
system. may occur.
NOTE: There will be a slight drop in the
10. Close the Power Steering Fill Adapter Manifold power steering fluid level in the reservoir when
control valve (vacuum side). the engine is started.
Start the engine and turn the steering wheel
11. Slowly open the Power Steering Fill Adapter from stop-to-stop.
Manifold control valve (fluid side).
16. Turn the ignition switch to the OFF position.
12. Once power steering fluid enters the fluid
reservoir and reaches the minimum fluid level 17. NOTE: Do not overfill the reservoir.
indicator line on the reservoir, close the Power
Steering Fill Adapter Manifold control valve Remove the reservoir cap and fill the reservoir
(fluid side). with the specified fluid.
18. Install the reservoir cap.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

GENERAL PROCEDURES
Power Steering System Filtering 4. Using a section of 3/8 in hose (approximately
101.6 mm [4 in] long) and clamps, attach the
Material other end of the filter to the fluid cooler.
Item Specification 5. Remove the hose pinch-off tool from the return
MERCON V Automatic MERCON V hose.
Transmission Fluid
XT-5-QM (or XT-5-QMC) 6. Check the power steering fluid level and add
(US); CXT-5-LM12 fluid as necessary.
(Canada)
NOTE: The intent of this procedure is to remove 7. Start the engine and allow it to run at idle for
contamination in the power steering system that has approximately 15 seconds.
resulted in a brake pedal kickback condition. This is
accomplished by installing a temporary filter 8. NOTICE: Do not hold the steering wheel at
(7B155) in-line with the power steering system. the stops for an extended amount of time.
The filter should be installed in-line between the Damage to the power steering pump may
steering gear and the fluid cooler or in-line between occur.
the fluid cooler and the fluid reservoir. If the brake Turn the steering wheel lock-to-lock 10 times.
pedal kickback condition still exists after carrying
out the filtering procedure, a new Hydro-Boost 9. Fully apply the brake pedal (hard to the floor)
brake booster must be installed. 25 times.
1. With the vehicle in NEUTRAL, position it on a 10. Turn the steering wheel lock-to-lock 5 times.
hoist. For additional information, refer to
Section 100-02. 11. Remove and discard the filter.
• Connect the return hose to the fluid cooler.
2. Using a suitable tool, pinch-off the return hose
to prevent fluid loss when the hose is 12. Fill the power steering system. Refer to Power
disconnected. Steering System Filling in this section.
3. Release the clamp and disconnect the return 13. Start the engine and with the engine at idle,
hose from the the fluid cooler. gradually apply the brake pedal until fully
• Cap the fluid cooler port to minimize fluid applied. If the brake pedal kickback condition
loss. still exists, install a new Hydro-Boost brake
booster. For additional information, refer to
• Install the temporary filter in-line with the
Section 206-07.
return hose using the original hose clamp to
retain the filter.

GENERAL PROCEDURES
Power Steering System Flushing 9. NOTICE: Do not allow the power steering
pump to run completely dry of power
Material steering fluid. Damage to the power steering
pump may occur.
Item Specification
Start the engine while simultaneously turning
Transmission Fluid
the steering wheel to lock and then immediately
XT-5-QM (or XT-5-QMC) turn the ignition switch to the OFF position.
(US); CXT-5-LM12
(Canada) 10. NOTE: Avoid turning the steering wheel
without the engine running as this may cause
NOTICE: Do not mix fluid types. Any mixture or air to be pulled into the steering gear.
any unapproved fluid may lead to seal
NOTE: Do not overfill the reservoir.
deterioration and leaks. A leak may ultimately
cause loss of fluid, which may result in a loss of Fill the reservoir as needed with the specified
power steering assist. fluid.
1. Remove the power steering fluid reservoir cap. 11. Repeat Steps 8 and 9, turning the steering
wheel in the opposite direction each time, until
2. Using a suitable suction device, remove the the fluid exiting the power steering fluid return
power steering fluid from the reservoir. hose is clean and clear of foreign material.
3. Release the clamp and disconnect the return 12. Remove the extension hose from the return
hose from the reservoir. hose.
• Remove the clamp from the hose and allow
the remaining fluid to drain out of the 13. Remove the plug from the fluid reservoir inlet
reservoir. port.
4. Plug the power steering fluid reservoir inlet 14. Install the clamp and connect the power
port. steering return hose to the reservoir.
5. Attach an extension hose to the return hose. 15. NOTE: It is necessary to correctly fill the
power steering system to remove any trapped
6. NOTE: Do not reuse the power steering fluid air and completely fill the power steering
that has been flushed from the power steering system components.
system. If, after correctly filling the power steering
Place the open end of the extension hose into a system, there is power steering noise
suitable container. accompanied by evidence of aerated fluid and
there are no fluid leaks, it may be necessary to
7. If equipped with Hydro-Boost, apply the purge the power steering system. For additional
brake pedal 4 times. information, refer to Power Steering System
8. NOTE: Do not overfill the reservoir. Fill the power steering system. For additional
Fill the reservoir as needed with the specified information, refer to Power Steering System
fluid. Filling in this section.

GENERAL PROCEDURES
Power Steering System Purging
Special Tool(s)
Evacuation Cap, Power Steering
211-265
Vacuum Pump Kit

416-D002 (D95L-7559-A) or
equivalent 4. Start the engine.
5. Using the Vacuum Pump Kit, apply vacuum

and maintain the maximum vacuum of 68-85
kPa (20-25 in-Hg).
Material • If the Vacuum Pump Kit does not maintain
vacuum, check the power steering system
Item Specification for leaks before proceeding. For additional
MERCON V Automatic MERCON V information, refer to Power Steering Fluid
Transmission Fluid Leak Test in this section.
(US); CXT-5-LM12
(Canada) 6. If equipped with Hydro-Boost, apply the
brake pedal 4 times.
NOTICE: If the air is not purged from the power
steering system correctly, premature power 7. NOTICE: Do not hold the steering wheel
steering pump failure may result. The condition against the stops for an extended amount of
may occur on pre-delivery vehicles with evidence time. Damage to the power steering pump
of aerated fluid or on vehicles that have had may occur.
steering component repairs. Cycle the steering wheel fully from stop-to-stop
10 times.
1. NOTE: A whine heard from the power steering
pump can be caused by air in the system. The 8. Stop the engine.
power steering purge procedure must be carried
out prior to any component repair for which 9. Release the vacuum and remove the Vacuum
power steering noise complaints are Pump Kit and the Power Steering Evacuation
accompanied by evidence of aerated fluid. Cap.
Remove the power steering reservoir cap.
Check the fluid. 10. NOTE: Do not overfill the reservoir.
Fill the reservoir as needed with the specified
2. Raise the front wheels off the floor. Refer to fluid.
the appropriate section in Group 100 for the
procedure. 11. Start the engine.
3. Tightly insert the Power Steering Evacuation

Cap into the reservoir and connect the Vacuum
Pump Kit.

12. Install the Power Steering Evacuation Cap and 13. NOTICE: Do not hold the steering wheel
the Vacuum Pump Kit. Apply and maintain the against the stops for an extended amount of
maximum vacuum of 68-85 kPa (20-25 in-Hg). time. Damage to the power steering pump
may occur.
Cycle the steering wheel fully from stop-to-stop
10 times.
14. Stop the engine, release the vacuum and

remove the Vacuum Pump Kit and the Power
Steering Evacuation Cap.
15. NOTE: Do not overfill the reservoir.

Fill the reservoir as needed with the specified
fluid and install the reservoir cap.
16. Visually inspect the power steering system for

leaks.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

GENERAL PROCEDURES
Steering Gear Meshload Adjustment
— F-250, F-350
Special Tool(s)
Remover, Steering Arm
211-003 (T64P-3590-F) or
equivalent
All vehicles 6. Rotate the steering wheel to the left stop and
then rotate the steering wheel back
1. NOTE: The engine should not be running. approximately 45 degrees.
Turn the steering wheel from right lock-to-left
lock at least once. 7. NOTE: The peak preload torque must be
within 0.34-1.36 Nm (3-12 lb-in) or a new
2. Remove the driver air bag. For additional steering gear must be installed. For additional
information, refer to Section 501-20B. information, refer to Section 211-02.
Attach an inch pound torque wrench to the
3. With the vehicle in NEUTRAL, position it on a steering wheel bolt and slowly and evenly
hoist. For additional information, refer to rotate the steering wheel clockwise one-half
Section 100-02. turn (180 degrees).
• Record the peak preload torque.
4. Remove the drag link nut and cotter pin.
8. Rotate the steering wheel to its centered
position (approximately one and one-half turns
from either stop). Place the torque wrench on
the steering wheel bolt with the handle in the
vertical position. Rotate the torque wrench
slowly and evenly one-fourth turn (90 degrees)
from each side of center.
• Record the peak on-center torque.
9. NOTE: The on-center torque must be 1.01-1.47

Nm (7-12 lb-in) greater than preload torque
without exceeding a total of 2.32 Nm (20.5
lb-in). The on-center torque minus the preload
5. Using the Steering Arm Remover, separate the torque is the meshload torque.
drag link from the pitman arm. If necessary, carry out the following steps to
adjust the on-center torque.
Vehicles with 6.4L diesel
10. Remove the upper cooling fan shroud. For

additional information, refer to Section 303-03.

All vehicles
11. NOTE: Rotate the meshload screw clockwise

to increase and counterclockwise to decrease.
Hold the meshload screw, loosen the locknuts
and then adjust the meshload screw to the
correct rotating torque.
14. Position the drag link, and install the nut and
cotter pin.
• Tighten to 200 Nm (148 lb-ft).
12. Verify that the on center torque is to

specification.
• Readjust if necessary.
13. Hold the meshload screw and tighten the

locknut to 31 Nm (23 lb-ft).
• Tighten the jam nut to 17 Nm (150 lb-in).
Vehicles with 6.4L diesel
15. Install the upper cooling fan shroud. For

All vehicles
16. Install the driver air bag. For additional

information, refer to Section 501-20B.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

211-02-i Power Steering 211-02-i
SECTION 211-02 Power Steering

CONTENTS PAGE
Power Steering Fluid Reservoir .......................................................................................................................................... 211-02-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

211-02-2 Power Steering 211-02-2
Power Steering Fluid Reservoir
Material
Item Specification
MERCON® V Automatic Transmission Fluid MERCON® V
XT-5-QM (or XT-5-QMC) (US); CXT-5-LM12 (Canada)
NOTE:
Vehicles with 6.4L engine shown, 5.4L and 6.8L engines similar.
Item Part Number Description

1 8D011 Fuel charge cooler tube (diesel only)
2 3R700 Power steering fluid reservoir
3 3A713 Power steering supply hose-to-power steering fluid cooler hose
4 3A713 Hydro-Boost® supply hose (hydraulic booster only)
5 3691 Power steering pump supply hose
6 W503924 Power steering fluid reservoir bolts (2 required)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
Removal and Installation
NOTICE:
While repairing the power steering system, care should be taken to prevent the entry of contaminants or failure of the power steering components
may result.
All vehicles
1. Using a suitable suction device, drain the power steering fluid reservoir.
2. Release the clamp and disconnect the power steering pump supply hose.
3. Release the clamp and disconnect the power steering supply hose-to-power steering fluid cooler hose.
Vehicles with Hydro-Boost®
4. Release the clamp and disconnect the hydraulic booster supply hose.
Vehicles with 6.4L engine
5. Disconnect the fuel charge cooler hose from the fluid reservoir.
All vehicles
6. NOTE:
The fluid reservoir bolts have a dry adhesive on the threads and should not be reused.
Remove the 2 power steering fluid reservoir bolts.

• Discard the bolts.
• To install, tighten the new bolts to 7 Nm (62 lb-in).
7. To install, reverse the removal procedure.
8. Fill the power steering system. For additional information, refer to Section 211-00.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

SPECIFICATIONS
General Specifications (Continued)
Material
Item Specification
Item Specification Fill Capacity
Flow 10.6-12.0 L/min
Dye-Lite — — (2.8-3.2 gpm)
ATF/Power Fluid @ 74-80°C
Steering Fluid Leak (165-175°F)
Detection Dye Engine at idle
164-R3701
(Rotunda) Minimum Capacity 5.3 L/min
(1.4 gpm)
MERCON V MERCON V F-250/350 Fluid @ 74-80° C
Automatic 2,306 ml (165-175°F)
Transmission Fluid (2.5 qt) Engine at idle
XT-5-QM (or F-450/550 Pressure 5,171 kPa
XT-5-QMC) (US); 3,257 ml (750 psi)
CXT-5-LM12 (3.5 qt)a
(Canada) Power steering purge 68-85 kPa (20-25 in/Hg)
vacuum
a Capacities listed are average system capacities and
may vary. Pressure 1,034 kPa (150 psi)
Fluid @ 74-80°C
General Specifications (165-175°F)
Engine at idle
Item Specification Relief pressure 12,066-12,755 kPa
Power Steering Gear F-250/350 (1,750-1,865 psi)
Meshload 1.01-1.47 Nm (9-13 lb-in) a Refer to Component Test in this section.
Meshload + preload 2.32 Nm (20.5 lb-in)
(maximum) Torque Specifications
Steering gear preload 0.34-1.36 Nm (3-12 lb-in)
Description Nm lb-ft lb-in
Turns lock-to-lock 4.0
Drag link nut 200 148 —
Steering linkage —
vertical/lateral deflectiona Meshload adjusting 17 — 150
screw jam nut
Power Steering Pump
Meshload adjusting 31 23 —
screw locknut


CONTENTS PAGE

Power Steering ................................................................................................................................................................... 211-02-2
Power Steering System ................................................................................................................................................ 211-02-2
Power Steering Pump ................................................................................................................................................... 211-02-2
Steering Gear ............................................................................................................................................................... 211-02-2
Steering Gear Identification .......................................................................................................................................... 211-02-2
Power Steering Pump Identification ............................................................................................................................. 211-02-3
2008 F-250, 350, 450, 550 Super Duty, 7/2007


Power Steering
Power Steering System
The power steering system consists of the following components:
• Power steering pump

• Power steering fluid reservoir
• Power steering pressure lines
• Power steering return lines
• Power steering fluid cooler
• Steering gear
The power steering system uses a vane-type pump to move the fluid from the reservoir to the steering gear and through the rest of the steering hydraulic
system. The power steering pump is mounted to the engine and driven by the engine accessory drive belt. Power steering fluid flows into the pump from the
reservoir. The power steering fluid is trapped between the pump vanes and moved to the high-pressure side of the pump creating a flow of fluid. The
restriction of this flow by the steering gear creates the pressure that provides the steering assist. A combined pressure relief/flow valve is built into the pump
to control the maximum pressure and flow provided to the steering system. This action prevents damage to the system and provides the correct level of assist
during all engine speeds. While under pressure, the power steering fluid flows through the high-pressure power steering line to the steering gear. The fluid
exits the gear and flows through the return line, the cooler and finally to the reservoir. The reservoir slows the fluid, allowing air to escape and filters the
fluid before returning it to the pump.
Some vehicles are equipped with a Hydro-Boost® brake booster. The Hydro-Boost® brake booster is a hydraulically operated brake booster powered by the
power steering pump. The power steering pump provides the fluid pressure to operate both the power brake booster and the power steering gear.
A Hydro-Boost® reserve system (accumulator) stores sufficient fluid under pressure to provide at least 2 power-assisted brake applications in the event the
power steering pump fluid flow is interrupted. The brakes can also be applied manually if the reserve system is depleted.
Power Steering Pump

The power steering pump has the following features:
• A belt-driven, vane-type pump

• An identification tag indicating the model number and bar code
• Is replaced as an assembly
Steering Gear
The steering gear has the following features:
• A torsion bar-type, hydraulic-assisted system

• Reduces road shock and vibration
• Uses a rotary-style hydraulic valve
Steering Gear Identification
NOTE:
Always use the identification code when ordering replacement parts.
An identification tag may be attached to the valve housing.
F-250/350 Steering Gear
2008 F-250, 350, 450, 550 Super Duty, 7/2007

DESCRIPTION AND OPERATION (Continued)
Item Description
1 Model code
2 Year
3 Month
4 Day of month
5 Shift
6 For manufacturing purposes only
Item Description
1 Model code
2 Ford production part number
3 Date code (DD/MM/YY)
4 Production number
5 Shift
6 Manufacturing purposes only
Power Steering Pump Identification
NOTE:
Always use the identification code when ordering replacement parts.
The pump identification code is located on a tag attached to the power steering pump.
Item Description
1 Model code
2008 F-250, 350, 450, 550 Super Duty, 7/2007

DESCRIPTION AND OPERATION (Continued)
(Continued)
Item Description
2 For manufacturing purposes only
3 Day of the month
4 Shift
5 Month
6 Year
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE

Power Steering ................................................................................................................................................................... 211-02-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007


Power Steering
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Steering Gear — F-250, F-350 ............................................................................................................................................ 211-02-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Steering Gear — F-250, F-350

Special Tool(s)
Holding Fixture, Transmission

307-003 (T57L-500-B)
Installer, Steering Gear Bushing

211-008 (T65P-3524-A3)
Installer, Worm Bearing Locknut

211-012 (T66P-3553-B)
Remover/Installer, Steering Gear Bearing

211-007 (T65P-3524-A2)
Remover/Installer, Steering Gear Oil Seal

211-006 (T65P-3524-A1)
Material
Item Specification
Multi-Purpose Grease ESB-M1C93-B
XG-4 and/or XL-5
Threadlock and Sealer WSK-M2G351-A5
TA-25
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)

1 19G405 Meshload adjusting screw jam nut
2 — Meshload adjusting screw locknut (part of 3L548 seal kit)
3 N808939 Sector shaft housing cover bolt (4 required)
4 — Sector shaft housing cover
5 — Sector shaft housing cover seal (part of 3L548 seal kit)
6 — Sector shaft and meshload adjusting screw assembly (part of 3504)
7 — Steering gear housing (part of 3504)
8 — Sector shaft seal (part of 3L548 seal kit)
9 — Spacer (part of 3L548 seal kit)
10 — Snap ring (part of 3L548 seal kit)
11 — Sector shaft dust seal (part of 3L548 seal kit)
12 — Valve housing-to-gear housing O-ring seal (part of 3L548 seal kit)
13 — Worm thrust bearing retainer ring (part of 3504)
14 — Piston assembly (part of 3504)
15 — Valve housing seal (part of 3L548 seal kit)
16 — Worm thrust bearing retainer ring setscrew (part of 3L548 seal kit)
17 — Valve housing (part of 3504)
18 3885578 Valve housing bolt (4 required)
19 — Input shaft bearing (part of 3504)
20 — Input shaft seal (part of 3L548 seal kit)
21 — Snap ring (part of 3L548 seal kit)
22 — Input shaft dust seal (part of 3L548 seal kit)
NOTICE:
While repairing the power steering system, care should be taken to prevent the entry of contaminants, or premature failure of the power steering
components may result.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
NOTE:
The steering gear piston assembly cannot be repaired or installed separately.
1. Remove the steering gear. For additional information, refer to Steering Gear — 5.4L, 6.8L or Steering Gear — 6.4L Diesel in this section.
Disassembly
1. NOTICE:
Use a soft-jawed vise to secure the steering gear or damage to the steering gear housing may occur.
Secure the steering gear in a soft-jawed vise. Use protective caps on the vise jaws.
2. Rotate the steering gear input shaft from stop-to-stop and record the number of rotations.
• Rotate the input shaft in the opposite direction one-half of the total rotations recorded to center the gear.
3. Remove the meshload adjusting screw jam nut.
4. Remove and discard the meshload adjusting screw locknut.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
5. Remove the 4 steering gear sector shaft housing cover bolts.
6. NOTICE:
If there is evidence of damage, scratches or wear to the steering gear/sector shaft housing sealing area, a new steering gear must be installed
or a fluid leak may occur.
Rotate the meshload adjusting screw clockwise until the sector shaft housing cover is separated from the adjuster screw.
• Inspect the sector shaft housing cover bore.
7. Remove and discard the sector shaft housing cover seal.
8. NOTICE:
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
If there is evidence of damage, scratches or wear to the sector shaft, a new steering gear assembly must be installed or a fluid leak may occur.
Using a soft mallet, gently tap on the lower end of the sector shaft and remove the sector shaft.
9. Remove the 4 valve housing bolts.
10. Remove the valve housing and piston assembly.
11. Remove and discard the valve housing seal.
12. Place the valve housing in the Transmission Holding Fixture and remove the worm thrust bearing retainer ring setscrew.
• Discard the setscrew.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
13. Using the Worm Bearing Locknut Installer, remove the worm thrust bearing retainer ring.
14. Remove the input shaft and control from the valve housing.
15. Rotate the holding fixture 180 degrees.

16. NOTICE:
Do not allow the screwdriver to make contact with the valve housing bore, or damage to the sealing area may occur, causing a fluid leak.
Using a screwdriver, remove and discard the input shaft dust seal.
17. Remove and discard the input shaft seal snap ring.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
18. Rotate the holding fixture 180 degrees.

19. Using the Steering Gear Bearing Remover/Installer and the Steering Gear Bushing Installer, remove the input shaft bearing and input shaft seal.
• Discard the input shaft seal.
20. Remove the valve housing from the holding fixture.

21. Reposition the steering gear in the vise to access the sector shaft seals.
22. NOTICE:
Do not allow the screwdriver to make contact with the sector shaft seal bore, or damage to the sealing area may occur, causing a fluid leak.
Using a screwdriver, remove and discard the sector shaft dust seal.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
23. Remove the sector shaft seal snap ring and spacer.
• Discard the snap ring.
24. NOTICE:
Do not allow the seal puller to make contact with the sector shaft seal bore, or damage to the sealing area may occur, causing a fluid leak.
NOTE:
The steering gear sector shaft bearing is not servicable.
Using a suitable seal puller, remove and discard the sector shaft seal.
• Inspect the sector shaft seal bore.
25. Remove and discard the valve housing-to-gear housing O-ring seal.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

211-02-10 Power Steering 211-02-10
(Continued)
Assembly
1. Lubricate the sector shaft seal bore with multi-purpose grease.
2. NOTE:
Lubricate the sector shaft seal and spacer with multi-purpose grease.
Position the new sector shaft seal and the spacer on the Steering Gear Oil Seal Remover/Installer, and using a press, install the new sector shaft seal
and the spacer.
• Press the seal and spacer until the spacer is slightly below the snap ring groove.
3. Install the new sector shaft seal snap ring.
4. NOTE:
Place the sector shaft dust seal on the Steering Gear Oil Seal Remover/Installer so the raised lip is toward the tool.
Position the new sector shaft dust seal on the Steering Gear Oil Seal Remover/Installer, and using the press, install the new sector shaft dust seal.
• Lubricate the steering gear sector shaft dust seal with multi-purpose grease.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

211-02-11 Power Steering 211-02-11
(Continued)
5. Position the input shaft bearing in the valve housing and use the press and the Steering Gear Oil Seal Remover/Installer to seat the bearing.
6. Using the press and the Steering Gear Oil Seal Remover/Installer, install the new input shaft seal.
7. Install the new input shaft housing snap ring.

• Lubricate the top of the input shaft seal with multi-purpose grease.
8. NOTE:
Place the input shaft dust seal on the Steering Gear Bearing Remover/Installer so the raised lip is toward the tool.
Using the Steering Gear Bearing Remover/Installer and the Steering Gear Bushing Installer, install the new input shaft dust seal.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

211-02-12 Power Steering 211-02-12
(Continued)
9. Mount the valve housing to the Transmission Holding Fixture.
10. Install the input shaft and control into the valve housing.
11. Position the steering gear worm thrust bearing retainer ring into the valve housing.
12. Using the Worm Bearing Locknut Installer, tighten the worm thrust bearing retainer ring.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

211-02-13 Power Steering 211-02-13
(Continued)
13. Install the new worm thrust bearing retainer ring setscrew.
• Tighten to 2 Nm (18 lb-in).
14. Secure the steering gear housing in the soft-jawed vise.

15. Install the new valve housing-to-gear housing O-ring seal.
16. Install the new valve housing seal.
17. Lubricate the piston seal with multi-purpose grease.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

211-02-14 Power Steering 211-02-14
(Continued)
18. Install the piston assembly into the steering gear housing.
19. Rotate the input shaft from stop-to-stop and record the number of rotations.
• Rotate the input shaft one-half of the total rotations to align the piston for correct sector shaft installation.
20. Install the sector shaft into the steering gear housing.
21. Apply threadlock and install the 4 valve housing bolts.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

211-02-15 Power Steering 211-02-15
(Continued)
22. Install a new O-ring on the sector shaft housing cover and lubricate with multi-purpose grease.
23. Place the sector shaft housing on the meshload adjusting screw and rotate the adjusting screw counterclockwise until the sector shaft housing cover is
drawn into the steering gear housing and the adjusting screw bottoms out.
24. Using a soft mallet, gently tap on the meshload adjusting screw to fully seat the sector shaft housing.
25. Apply threadlock and loosely install the 4 sector shaft housing cover bolts.
26. NOTICE:
Do not exceed 30 Nm (22 lb-ft) when applying pressure to the sector shaft housing or damage to the housing may occur.
Install an original steering gear mounting bolt into the steering gear housing, applying pressure to the side of the sector shaft housing.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

211-02-16 Power Steering 211-02-16
(Continued)
• Tighten the steering gear mounting bolt to 25 Nm (18 lb-ft).
27. Tighten the 4 sector shaft housing cover bolts to 68 Nm (50 lb-ft).
• Remove the steering gear mounting bolt.
28. NOTICE:
A new meshload adjusting screw locknut must be installed or a fluid leak at the meshload adjusting screw may occur.
NOTE:
The meshload adjusting screw locknut will be tightened during the steering gear meshload adjustment. Do not tighten the locknut at this time.
Loosely install the meshload adjusting screw locknut.
29. Rotate the input shaft to the left stop and then back-off approximately 45 degrees.
30. Using a dial or digital torque wrench and a crowfoot wrench, slowly and evenly rotate the input shaft clockwise one-half turn (180 degrees), starting
from the 45 degree position. This torque reading is the preload torque.
• Record the preload torque.
• The preload torque must be within 0.34-1.36 Nm (3-12 lb-in).
2008 F-250, 350, 450, 550 Super Duty, 7/2007

211-02-17 Power Steering 211-02-17
(Continued)
31. Rotate the input shaft to its center of travel (approximately 1.5 turns from either stop). Place the torque wrench on the input shaft with the handle in
the vertical position. Rotate the torque wrench slowly and evenly one-quarter turn (90 degrees) from each side of center. This torque reading is the on-
center torque.
• Record the torque measured on or near center.
32. NOTE:
The on-center torque must be 1.01-1.47 Nm (9-13 lb-in) greater than preload torque without exceeding a total of 2.32 Nm (20.5 lb-in). The on-center
torque minus the preload torque is the meshload torque.
If necessary, carry out the following steps to adjust the on-center torque.
33. NOTE:
Rotate the meshload adjusting screw clockwise to increase the on-center torque and counterclockwise to decrease the on-center torque.
Rotate the meshload adjusting screw until the on-center and meshload torque readings fall within the specified values.
34. While holding the meshload adjusting screw, tighten the meshload adjusting screw locknut to 31 Nm (23 lb-ft).
35. Install the meshload adjusting screw jam nut.

• Tighten to 17 Nm (150 lb-in).
2008 F-250, 350, 450, 550 Super Duty, 7/2007

211-02-18 Power Steering 211-02-18
(Continued)
36. Install the steering gear. For additional information, refer to Steering Gear — 5.4L, 6.8L or Steering Gear — 6.4L Diesel in this section.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Hydraulic Booster to Steering Gear Pressure Line ............................................................................................................. 211-02-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Hydraulic Booster to Steering Gear Pressure Line
Material
Item Specification
Hydraulic Booster-to-Steering Gear Pressure Line
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)

1 — Pressure line-to-jumper line fitting (part of 3A719)
2 — Pressure line retainer (part of 3A717)
3 — Pressure line-to-steering gear fitting (part of 3A719)
4 14A206 Power steering line retainer
5 — Power steering line retainer (5.4L, 6.8L engines only) (part of
3A717)
6 — Return hose-to-steering gear fitting (part of 3A713)
7 N803257 O-ring seal
8 — Return hose clip (part of 3A713)
9 3F540 Steering gear shield
10 — ABS module electrical connector (part of 14405)
11 2C219 Hydraulic Control Unit (HCU)
12 3A719 Hydraulic booster-to-steering gear pressure line

2 3B743 Jumper line
3 — Jumper line fitting (part of 3B743)
4 382802 Jumper line bracket nut
NOTICE:
may result.
NOTE:
The jumper line can be serviced separately. It is not necessary to remove the jumper line from the hydraulic booster when servicing the pressure line.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
All vehicles
2. Remove the fender splash shield. For additional information, refer to Section 501-02.
3. Disconnect and position aside the ABS module electrical connector.
4. Disconnect the steering gear shield from the line fitting and position the shield up on the lower steering column shaft.
F-250/350 vehicles
5. Disconnect the return hose-to-steering gear fitting.
• Discard the O-ring seal.
• To install, tighten to 35 Nm (26 lb-ft).
6. Unclip the return hose from the retainer clip.
All vehicles
7. Disconnect the pressure line-to-steering gear fitting.
8. Disconnect the pressure line-to-jumper line fitting.
9. Unclip the hydraulic booster-to-steering gear pressure line from the 2 pressure line retainers and remove the pressure line.
• Install a new O-ring seal on the return hose-to-steering gear fitting.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Power Steering Fluid Cooler ............................................................................................................................................... 211-02-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Power Steering Fluid Cooler
Material
Item Specification

1 — Hose clamp (part of 3A713)
2 3A713 Reservoir-to-fluid cooler return hose
3 — Hose clamp (part of 3A713)
4 3A713 Steering gear-to-fluid cooler return hose
5 W711851 Power steering fluid cooler bolts
6 3D746 Power steering fluid cooler
7 — Hood release cable retainer
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
NOTICE:
While repairing the power steering system, care should be taken to prevent the entry of foreign material or failure of the power steering
1. Release the clamps and disconnect the 2 hoses.

2. Unclip the hood release cable.
3. Remove the 2 bolts and the power steering fluid cooler.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Power Steering Pump — 6.4L Diesel .................................................................................................................................. 211-02-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Power Steering Pump — 6.4L Diesel

Special Tool(s)
Installer Set, Teflon® Seal

211-D027 (D90P-3517-A) or equivalent
Material
Item Specification

1 — Pressure line-to-pump fitting (part of 3A717)
2 388898 Teflon® seal
3 3A717 Hydraulic booster-to-power steering pump pressure line
4 W700839 Power steering pump bolts (3 required)
5 3691 Power steering pump supply hose
6 3A674 Power steering pump
7 W520112 Pressure line/supply hose bracket nut
NOTICE:
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
NOTE:
New Teflon® seals must be installed any time the power steering line fittings are disconnected.
1. Remove the power steering pump pulley. For additional information, refer to Power Steering Pump Pulley in this section.
2. Remove the pressure line/supply hose bracket nut.
• To install, tighten to 18 Nm (159 lb-in).
3. Release the clamp and disconnect the power steering pump supply hose.
4. Disconnect the pressure line-to-pump fitting.
• Remove and discard the Teflon® seal.
5. Remove the 3 bolts and the power steering pump.
6. NOTE:
Make sure that the power steering pump bolts are installed in their original positions.
NOTE:
Thoroughly clean all foreign material from the pressure line-to-pump threads before installing the fitting.
To install, reverse the removal procedure.

• Using the Teflon® Seal Installer Set, install a new Teflon® seal on the pressure line fitting.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Power Steering Pump Pulley .............................................................................................................................................. 211-02-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Power Steering Pump Pulley

Special Tool(s)
Installer, Power Steering Pump Pulley

211-185 (T91P-3A733-A)
Remover, Power Steering Pump Pulley

211-016 (T69L-10300-B)
NOTE:
Vehicles with 6.4L engine shown, 5.4L and 6.8L engine similar.

1 3D763 Power steering pump pulley
Removal
1. Remove the engine cooling fan. For additional information, refer to Section 303-03.
2. Rotate the accessory drive belt tensioner and remove the accessory drive belt from the power steering pump pulley.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
Vehicles with 5.4L and 6.8L engine
3. Rotate the accessory drive belt tensioner and remove the accessory drive belt from the power steering pump pulley.
• For vehicles with A/C, rotate the tensioner clockwise.
• For vehicles without A/C, rotate the tensioner counterclockwise.
4. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02.
All vehicles
5. Using the Power Steering Pump Pulley Remover, remove the pulley.
• Inspect the pulley for paint marks in the web area near the hub. If there are 2 paint marks, discard the pulley. If there is no paint or one paint
mark, use a paint pencil to mark the web area of the pulley near the hub.
Installation
All vehicles
1. NOTICE:
Installation of a new power steering pump pulley is necessary after being removed and installed 2 times, or pulley and/or pump failure may
occur.
Using the Power Steering Pump Pulley Installer, install the power steering pump pulley.

2. Rotate the accessory drive belt tensioner and install the accessory drive belt on the power steering pump pulley.
• For vehicles with A/C, rotate the tensioner clockwise.
• For vehicles without A/C, rotate the tensioner counterclockwise.
3. Install the engine cooling fan. For additional information, refer to Section 303-03.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Power Steering Pump to Hydraulic Booster Pressure Line — 6.4L Diesel .......................................................................... 211-02-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Power Steering Pump to Hydraulic Booster Pressure Line — 6.4L Diesel
Material
Item Specification

2 3A717 Power steering pump-to-hydraulic booster pressure line
3 — Pressure line bracket (part of 3A717)
4 — Supply hose bracket (part of 3691)
5 W520112 Pressure line/supply hose bracket nut
6 14A206 Pressure line retainer
9 3B743 Jumper line
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)

10 — Jumper line fitting (part of 3B743)
NOTICE:
1. Using a suitable suction device, remove the power steering fluid from the reservoir.
2. Remove the power steering pump pulley. For additional information, refer to Power Steering Pump Pulley in this section.
3. NOTE:
The jumper line can be serviced separately. It is not necessary to remove the jumper line from the hydraulic booster when servicing the pressure line.
Disconnect the pressure line-to-jumper line fitting.

4. Unclip the pressure line from the line retainer at the hydraulic booster.
5. Unclip the pressure line from the retainer near the Hydraulic Control Unit (HCU).
6. Unclip the pressure line from the retainer on the HCU.
7. Remove the pressure line/supply hose bracket nut and position the supply hose aside.
8. Disconnect the pressure line-to-pump fitting and remove the pressure line.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Power Steering Pump to Steering Gear Pressure Line ...................................................................................................... 211-02-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Power Steering Pump to Steering Gear Pressure Line
Material
Item Specification

2 3A719 Power steering pump-to-steering gear pressure line
5 3A713 Return hose
8 W701526 Pressure line bracket/pump bolt
NOTICE:
3. Remove the pressure line bracket/pump bolt.
4. Disconnect the pressure line-to-pump fitting.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
7. Disconnect the pressure line-to-steering gear fitting and remove the pressure line.
• Install a new O-ring seal on the return hose-to-steering gear fitting.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Steering Gear — 6.4L Diesel ............................................................................................................................................... 211-02-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Steering Gear — 6.4L Diesel

Special Tool(s)
Remover, Differential Bearing

205-008 (T57L-4220-A)

211-003 (T64P-3590-F)
Material
Item Specification
NOTE:
F-250/350 shown, F-450/550 similar.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)

3 14A206 Pressure line retainer
4 — Pressure line retainer (5.4L, 6.8L engines only) (part of 3A717)
5 3A719 Pressure line
6 W710643 Return hose-to-steering gear fitting
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)

10 3A713 Return hose
11 3E523 Pressure line retainers (2 required)
12 3504 Steering gear
13 3590 Sector shaft arm
14 W709296 Sector shaft arm-to-sector shaft nut
15 W710907 Nut retainer cap
16 712367 Inner drag link-to-sector shaft arm nut
17 N642569 Cotter pin
18 3B406 Drag link
19 N803942 Lower steering column shaft-to-steering gear bolt
21 W711886 Steering gear bolts (3 required) (F-250/350)
21 W711913 Steering gear bolts (3 required) (F-450/550)
NOTICE:
may result.
NOTICE:
The steering gear bolts must not be reused. The threads of the bolts are coated with a dry adhesive. When the bolts are removed, the dry adhesive is
degraded. If the bolts are reused, failure of the bolts and/or steering gear may occur.
All vehicles
2. Place the front wheels in the straight-ahead position.
• Remove the ignition key.
5. Disconnect the steering gear coupling shield from the line fitting and slide the shield upward on the intermediate shaft.
6. NOTICE:
Do not allow the steering column shaft to rotate while the intermediate shaft is disconnected or damage to the clockspring can result. If there
is evidence that the shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to Section 501-20B.
Remove the lower steering column shaft-to-steering gear bolt.

• Disconnect the lower steering column shaft from the steering gear.
7. Disconnect the pressure line-to-steering gear fitting.
9. Remove the cotter pin, retainer cap and the inner drag link-to-sector shaft nut in the following sequence.
1 Remove and discard the cotter pin.
2 Remove the sector shaft retainer cap and nut.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
▪ To install, tighten to 175 Nm (129 lb-ft).
10. Using the Steering Arm Remover, disconnect the inner drag link from the sector shaft arm.
F-250/350 vehicles
11. Remove the 3 bolts and the steering gear.
• To install, tighten the new bolts to 165 Nm (122 lb-ft).
F-450/550 vehicles
12. Remove the 3 bolts and the steering gear.
• To install, tighten the new bolts to 300 Nm (221 lb-ft).
All vehicles
13. NOTICE:
The sector shaft arm-to-sector shaft nut must not be reused. The threads of the nut are coated with a dry adhesive. When the nut is removed,
the dry adhesive is degraded. If the nut is reused, failure of the nut and/or sector shaft arm and shaft may occur.
Remove the sector shaft arm-to-sector shaft nut.

• Discard the nut.
• To install, tighten the new nut to 475 Nm (350 lb-ft).
F-250/350 vehicles
14. Using the Steering Arm Remover, remove the sector shaft arm.
F-450/550 vehicles
15. Using the Differential Bearing Remover and 2 Grade 8 bolts, 90 mm (3.54 in), separate the sector shaft arm from the steering gear.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
All vehicles
16. NOTICE:
New O-ring seals must be installed on the pressure and return line/hose fittings or a fluid leak may occur.

• Install a new cotter pin.
18. Check and, if necessary, adjust the front toe. For additional information, refer to Section 204-00.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Steering Gear to Fluid Cooler Return Hose ........................................................................................................................ 211-02-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Steering Gear to Fluid Cooler Return Hose
Material
Item Specification
NOTE:
Vehicles with 6.4L engine shown, 5.4L and 6.8L engine similar.

2 3A713 Power steering gear-to-fluid cooler return hose
3 — Steering gear-to-fluid cooler return hose retainer (part of 3A713)
(6.4L engine only)
5 3A713 Power steering fluid cooler jumper line (6.4L engine only)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)

6 3D746 Power steering fluid cooler
NOTICE:

1. Remove the air cleaner intake pipe. For additional information, refer to Section 303-12.
All vehicles
All vehicles
7. Unclip the steering gear-to-fluid cooler return hose from the 2 steering gear-to-fluid cooler return hose retainers.
8. Unclip the steering gear-to-fluid cooler return hose retainer from the fuel air charge cooler bracket.
9. Remove the left side fog lamp and bracket assembly. For additional information, refer to Section 417-01.
All vehicles
10. Release the steering gear-to-fluid cooler return hose clamp and remove the steering gear-to-fluid cooler return hose.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
SPECIFICATIONS ..................................................................................................................................................................... 211-02-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

SPECIFICATIONS
Material
MERCON® V Automatic Transmission Fluid MERCON® V Keep fluid level between MIN and MAX on
XT-5-QM (or XT-5-QMC) (US); CXT-5-LM12 reservoir
(Canada)
Multi-Purpose Grease ESB-M1C93-B —
XG-4 and/or XL-5
Threadlock and Sealer WSK-M2G351-A5 —
TA-25
General Specifications
Item Specification
Steering Gear F250/350
Meshload 1.01-1.47 Nm (9-13 lb-in)
Meshload + preload (maximum) 2.32 Nm (20.5 lb-in)
Steering gear preload 0.34-1.36 Nm (3-12 lb-in)
Torque Specifications

Drag link-to-sector shaft arm nut 175 129 —
Jumper line bracket nut 30 22 —
Jumper line-to-hydraulic booster fitting 27 20 —
Lower steering column shaft-to-steering gear bolt 48 36 —
Meshload adjusting screw jam nut 17 — 150
Meshload adjusting screw locknut 31 23 —
Power steering fluid cooler bolts 35 26 —
Power steering fluid reservoir bolts 7 — 62
Power steering pump bolts 25 18 —
Pressure line bracket/pump bolt (5.4L, 6.8L engines) 25 18 —
Pressure line-to-jumper line fitting 62 46 —
Pressure line-to-pump fitting 75 55 —
Pressure line-to-steering gear fitting 35 26 —
Pressure line/supply hose bracket nut (6.4L engine) 18 — 159
Return hose-to-steering gear fitting 35 26 —
Sector shaft arm-to-sector shaft nut 475 350 —
Sector shaft housing bolts a — — —
Steering gear bolts (F-250/350) 165 122 —

Steering gear bolts (F-450/550) 300 221 —
Valve housing bolts 54 40 —
Worm thrust bearing retainer ring 99 73 —
Worm thrust bearing retainer ring setscrew 2 — 18
a Refer to the procedure in this section.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

211-03-1 Steering Linkage 211-03-1

Steering Linkage • Outer drag link
The steering linkage consists of the following • Outer tie-rod end
components: • Tie-rod adjusting sleeve
• Sector shaft arm • Steering linkage damper
• Inner drag link • Steering linkage damper bracket
• Inner tie-rod end • Drag link adjusting sleeve


Steering Linkage

REMOVAL AND INSTALLATION

Drag Link — Inner, F-250 and F-350 6. NOTE: Count the number of turns required to
Four Wheel Drive (4WD), F-450, F-550 remove the inner drag link and adjusting sleeve
for reference during assembly.
Special Tool(s) NOTE: F-250/350 shown, F-450/550 similar.
Remover, Steering Arm Using the special tool, separate the inner drag
211-003 (T64P-3590-F) link from the sector shaft arm.
• Remove the inner drag link and adjusting
sleeve as an assembly.
WARNING: Never loosen, reposition or

deform the tie-rod adjusting sleeve aligner
bracket. Incorrect positioning of the tie-rod
adjusting sleeve clamps may result in steering
linkage binding and loss of vehicle control.
Failure to follow this instruction may result in
serious personal injury to the vehicle occupant(s).
1. Place the steering wheel in the straight-ahead 7. NOTE: Count the number of turns required to
position. remove the inner drag link for reference during
assembly.
2. With the vehicle in NEUTRAL, position it on a Separate the inner drag link from the adjusting
hoist. For additional information, refer to sleeve.
Section 100-02.
3. Loosen the outer adjusting sleeve clamp nut.

4. Remove the steering linkage damper-to-drag

link nut and separate the damper from the inner
drag link.
5. Remove the inner drag link cotter pin, nut

retainer and nut.
• Discard the cotter pin.

REMOVAL AND INSTALLATION (Continued)
8. CAUTION: Make sure that the inner
drag link nut retainer is correctly positioned
on the inner drag link nut to allow for cotter
pin installation. Do not tighten or loosen the
nut to align the retainer slot with the cotter
pin hole. Overtightening of the fasteners
may result in premature failure of steering
linkage components.
NOTE: Prior to fastening the steering linkage
damper, clean the damper surfaces of all
corrosion and dirt. Dirty, corroded damper
surfaces can conduct contaminants to the
damper seal and create a leak.
• Check and, if necessary, adjust the toe. For
additional information, refer to Section
204-00.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


Drag Link — Outer, F-250 and F-350 6. CAUTION: Make sure that the tie-rod
Four Wheel Drive (4WD), F-450, F-550 end nut retainer is correctly positioned to
allow for cotter pin installation. Do not
Special Tool(s) tighten or loosen the nut to align the retainer
slot with the cotter pin hole. Overtightening
C-Frame and Screw of the fasteners may result in premature
211-023 (T74P-3044-A1)
failure of steering linkage components.
NOTE: To avoid premature wear, position the
outer drag link so it is parallel with the wheel
knuckle before tightening the outer tie-rod end
nut.
1. Place the steering wheel in the straight-ahead 204-00.
position.
2. Remove the wheel and tire. For additional

information, refer to Section 204-04.
3. Loosen the outer adjusting sleeve clamp nut.

4. Remove the RH outer tie-rod end cotter pin, nut

retainer and nut.
X To install, tighten to 115 Nm (85 lb-ft).
5. NOTE: Count the number of turns required to

remove the outer drag link for reference during
assembly.
Using the special tool, disconnect the RH outer
tie-rod end from the outer drag link and the
wheel knuckle and then remove the outer drag
link.


Sector Shaft Arm 6. NOTE: F-250/350 shown, F-450/550 similar.
Using the special tool, separate the inner drag
Special Tool(s) link from the sector shaft arm.
211-003 (T64P-3590-F)
Remover, Differential Bearing

205-008 (T57L-4220-A)
F-250/350, 4WD and F-450/550 vehicles

7. Remove and discard the track bar
All vehicles bracket-to-frame bolt and nut.
1. Place the steering wheel in the straight-ahead
position. 8. Remove and discard the track bar
bracket-to-axle bolt and nut and remove the
2. With the vehicle in NEUTRAL, position it on a track bar.
hoist. For additional information, refer to • To install, tighten to 250 Nm (184 lb-ft).
Section 100-02.
All vehicles
F-250/350, four wheel drive (4WD) and
F-450/550 vehicles
9. NOTE: The sector shaft arm nut has a dry
adhesive on the threads. Do not reuse the sector
NOTE: To prevent the front suspension from shaft arm nut.
shifting when the track bar is removed, the front
suspension must be supporting the vehicle weight. Remove and discard the sector shaft arm nut.
3. Position the jackstand under the front axle
assembly.
4. Lower the vehicle until the front suspension is

supporting the vehicle weight.
All vehicles
5. Remove the inner drag link cotter pin, nut

retainer and nut.

F-250 and F-350 vehicles
10. Using the special tool, separate the sector shaft

arm from the sector shaft.
All vehicles
12. CAUTION: Make sure that the inner

drag link nut retainer is correctly positioned
on the inner drag link nut to allow for cotter
F-450 and F-550 vehicles
pin installation. Do not tighten or loosen the
nut to align the retainer slot with the cotter
11. Using the special tool and 2 grade 8 bolts, 90 pin hole. Overtightening of the fasteners
mm (3.54 in) long, separate the sector shaft arm may result in premature failure of steering
from the sector shaft. linkage components.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


Steering Linkage — Exploded View
F-250/350 Rear Wheel Drive (RWD)
Item Part Number Description Item Part Number Description

1 W711374 Outer drag link nut retainer 6 W520213 Adjusting sleeve clamp nuts
2 W711373 Outer drag link nut (2 required) (part of 3280)
3 N642569 Cotter pin (4 required) 7 — Drag link adjusting sleeve
aligner bracket (part of 3304)
4 3A131A Outer tie-rod end
8 3304 Inner drag link
5 3280 Adjusting sleeve (Continued)
(Continued)

9 W712055 Steering linkage damper 16 W706196 Steering linkage
frame bracket bolt plate and damper-to-drag link bracket
bolts bolt
10 W520114 Steering linkage damper 17 N620481 Steering linkage
frame bracket nuts (2 damper-to-drag link bracket
required) U-bolt nuts (4 required) (part
11 W520114 Steering linkage of 3304)
damper-to-frame bracket nut 18 — Steering linkage
12 3E651 Steering linkage damper damper-to-drag link bracket
(part of 3304)
13 3E652 Steering linkage damper
frame bracket 19 W520114 Steering linkage
damper-to-drag link bracket
14 W706196 Steering linkage nut
damper-to-frame bracket bolt
15 — Steering linkage
damper-to-drag link bracket
U-bolts (2 required) (part of
3304)
(Continued)
2008 F-250, 350, 450, 550 Super Duty, 7/2007


20 W712367 Inner drag link nut 28 W711374 Outer tie-rod end nut retainer
21 W710907 Inner drag link nut retainer 29 — Adjusting sleeve aligner
22 3590 Sector shaft arm bracket (part of 3A131B)
23 3A131B Inner tie-rod end 30 3281 Adjusting sleeve
24 W710907 Inner tie-rod end nut retainer 31 W520213 Adjusting sleeve clamp nuts
(2 required) (part of 3281)
25 W712367 Inner tie-rod end nut
32 3A131C Outer tie-rod end
26 W709296 Sector shaft arm nut
27 W711373 Outer tie-rod end nut
(Continued)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

NOTE: F-450/550 shown, F-250/350 four wheel drive (4WD) similar.

1 W520114 Steering linkage 5 3E651 Steering linkage damper
damper-to-frame bracket nut 6 706196 Steering linkage
2 3E652 Steering linkage damper damper-to-frame bracket bolt
frame bracket 7 3304B Inner drag link
3 W520114 Steering linkage damper 8 W520114 Steering linkage
frame bracket nuts damper-to-drag link nut
4 W712055 Steering linkage damper 9 N642569 Cotter pin (3 required)
frame bracket bolt plate and
bolts 10 3590 Sector shaft arm
(Continued) 11 W709296 Sector shaft arm nut
(Continued)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

12 W712367 Inner drag link nut 13 W710907 Inner drag link nut retainer
(Continued)

14 W520213 Adjusting sleeve clamp nuts 18 3281 Adjusting sleeve
(part of 3280) 19 3A130A RH outer tie-rod end
15 3304A Outer drag link 20 — Adjusting sleeve aligner
16 — Adjusting sleeve aligner bracket (part of 3A130A)
bracket (part of 3304B) 21 W711374 Outer tie-rod end nut retainer
17 3280 Adjusting sleeve (2 required)
(Continued) (Continued)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

22 W711373 Outer tie-rod end nut (2 25 3A130B LH outer tie-rod end
required)
23 W520213 Adjusting sleeve clamp nut (2 1. For additional information, refer to the
required) (part of 3281) procedures in this section.
24 — Adjusting sleeve aligner
bracket (part of 3A130B)
(Continued)
2008 F-250, 350, 450, 550 Super Duty, 7/2007


Steering Linkage Damper — F-250 3. Remove the steering linkage damper-to-frame
and F-350 Four Wheel Drive (4WD), bracket bolt and nut.
F-450, F-550 • To install, tighten the bolt to 103 Nm (76
lb-ft).
4. Remove the steering linkage damper-to-drag
link nut and remove the steering linkage
1. Place the steering wheel in the straight-ahead damper.
position.
• To install, tighten the nut to 90 Nm (66
2. With the vehicle in NEUTRAL, position it on a lb-ft).
hoist. For additional information, refer to
Section 100-02. 5. To install, reverse the removal procedure.


Tie Rod End — Outer, LH, F-250 and
F-350 Four Wheel Drive (4WD), F-450,
F-550
Special Tool(s)
Separator, Ball Joint
204-592
6. CAUTION: Make sure that the tie-rod

Removal and Installation end nut retainer is correctly positioned on
the tie-rod end nut to allow for cotter pin
1. Place the steering wheel in the straight-ahead installation. Do not tighten or loosen the nut
position. to align the retainer slot with the cotter pin
hole. Overtightening of the fasteners may
2. Remove the wheel and tire. For additional result in premature failure of steering
information, refer to Section 204-04. linkage components.
3. Loosen the LH outer tie-rod adjusting sleeve To install, reverse the removal procedure.
clamp nut. • Check and, if necessary, adjust the toe. For
• To install, tighten to 55 Nm (41 lb-ft). additional information, refer to Section
204-00.
4. Remove the LH outer tie-rod end cotter pin, nut
retainer and nut.

remove the LH outer tie-rod end for reference
during assembly.
Using the special tool, disconnect the LH outer
tie-rod end from the wheel knuckle and remove
the LH outer tie-rod end.


Tie Rod End — Outer, RH, F-250 and
F-350 Four Wheel Drive (4WD), F-450,
F-550
Special Tool(s)
C-Frame and Screw
211-023 (T74P-3044-A1)
1. Place the steering wheel in the straight-ahead

position.
2. Remove the wheel and tire. For additional

3. Loosen the RH outer tie-rod adjusting sleeve

clamp nut.
4. Remove the RH outer tie-rod end cotter pin, nut

retainer and nut.

remove the RH outer tie-rod end for reference
during assembly.
Using the special tool, disconnect the RH outer
tie-rod end from the drag link and wheel
knuckle and remove the RH outer tie-rod end.

6. CAUTION: Make sure that the tie-rod
end nut retainer is correctly positioned on
the tie-rod end nut to allow for cotter pin
installation. Do not tighten or loosen the nut
to align the retainer slot with the cotter pin
hole. Overtightening of the fasteners may
result in premature failure of steering
linkage components.
NOTE: To avoid premature wear, position the
outer drag link so it is parallel with the wheel
knuckle before tightening the outer tie-rod end
nut.
204-00.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

SPECIFICATIONS
Torque Specifications (Continued)
Steering linkage 103 76 —
Description Nm lb-ft lb-in damper-to-frame
Adjusting sleeve clamp 55 41 — bracket bolt (F-250/350
nuts four wheel drive
[4WD] and F-450/550)
Drag link — inner nut 175 129 —
Drag link — outer nut 115 85 — damper-to-frame
Sector shaft arm nut 475 350 — bracket nut (F-250/350
RWD)
damper frame bracket Tie-rod end — inner 175 129 —
nuts nut (F-250/350 RWD)
Steering linkage 90 66 — Tie-rod end — outer 115 85 —
damper-to-drag link nut
bracket nut Track bar ball joint nut 250 184 —
Steering linkage 25 18 — Track bar bracket nut 550 406 —
damper-to-drag link
bracket U-bolt nuts
(F-250/350 rear wheel
drive [RWD])

211-04-i Steering Column 211-04-i
SECTION 211-04 Steering Column

CONTENTS PAGE

Steering Column ................................................................................................................................................................. 211-04-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

211-04-2 Steering Column 211-04-2

Steering Column
The steering column system consists of the following components:
• Steering wheel
• Steering column
• Upper and lower steering column shafts
• Steering column switches
• Ignition lock cylinder
The steering column is the mechanical linkage between the steering wheel and the steering gear. The steering wheel is mounted to a shaft which passes
through the center of the steering column. The shaft is centered by roller bearings within the steering column. The steering column shaft then connects the
steering column to the steering gear. The steering column shaft utilizes U-joint type couplings. The tilt function of the steering column is controlled by a
mechanical lever on the side of the steering column which uses a cam to lock and unlock the steering column. When the tilt lever is unlocked, the steering
column can then be adjusted to various positions through a pin-type pivot. The steering column switches (multifunction and ignition) are mounted to the
steering column. These switches are covered by the upper and lower steering column shrouds.
For steering column switch service information, refer to Section 211-05.
For ignition lock cylinder service information, refer to Section 501-14.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE

Steering Column ................................................................................................................................................................. 211-04-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007


Steering Column
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
GENERAL PROCEDURES
Steering Wheel Wrap Bonding ........................................................................................................................................... 211-04-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

GENERAL PROCEDURES
Steering Wheel Wrap Bonding
Material
Item Specification
Instant Gel Adhesive WSK-M2G402-A4
TA-19
1. NOTE:
If re-adhering leather to the front side of the steering wheel only, it will not be necessary to remove the steering wheel. Steering wheel removal is
necessary only when repairing loose leather on the backside of the steering wheel.
If necessary remove the steering wheel. For additional information, refer to Steering Wheel in this section.
2. Position the loose leather out of the way.
3. Apply the specificed adhesive evenly over the wheel spoke.
4. Position the loose leather back into the original position.
5. NOTE:
The adhesive should be completely set after 5 minutes. Do not pull on the repair area.
Smooth the leather and tuck in for neat appearance.

• Apply pressure (for at least 30 seconds) until the leather is bonded to the wheel spoke.
6. If removed, Install the steering wheel. For additional information, refer to Steering Wheel in this section.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Steering Column Shaft ........................................................................................................................................................ 211-04-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Steering Column Shaft
NOTE:
F-350/450 shown, F-450/550 similar.

2 N803942 Lower steering column shaft-to-steering gear bolt
3 3C662 Lower steering column shaft
4 W710570 Upper steering column shaft-to-lower steering column shaft bolt
5 W705132 Steering column shaft dash seal bolt (2 required)
6 3D677 Upper steering column shaft dash seal
7 3E157 Upper steering column shaft
8 N808684 Upper steering column shaft-to-steering column bolt

1. With the vehicle in NEUTRAL, position the vehicle on a hoist. For additional information, refer to Section 100-02.
2. NOTE:
Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent).
Using a suitable holding device, hold the steering wheel in the straight-ahead position.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
3. Remove and discard the upper steering column shaft-to-steering column bolt.
• To install, tighten the new bolt to 28 Nm (21 lb-ft).
4. NOTICE:
Do not allow the steering column shaft to rotate while the intermediate shaft is disconnected or damage to the clockspring can result. If there
is evidence that the steering column shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to
Section 501-20B.
Rotate the steering wheel until the front wheels are back to the straight ahead position.
• Remove the ignition key.
• Disconnect the upper steering column shaft from the steering column.
5. Remove and discard the upper steering column shaft-to-lower steering column shaft bolt.
6. From the passenger compartment, remove the upper steering column shaft.
7. Separate the steering gear shield from the steering gear housing.
8. Remove and discard the lower steering column shaft-to-steering gear bolt.
9. Remove the lower steering column shaft.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Steering Column Shroud .................................................................................................................................................... 211-04-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Steering Column Shroud
NOTE:
Tilt column shown, fixed column similar.

1 04459 Steering column opening trim panel
2 3530A Upper steering column shroud
3 3530B Lower steering column shroud
4 W710485 Lower steering column shroud screws (3 required)
5 — Tilt lever dust boot (part of 3530B)
6 — Tilt lever screw (part of 3F609)
7 3F609 Tilt lever

All columns
1. Remove the steering column opening trim panel.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
Tilt columns
2. Remove the tilt lever dust boot.
3. Remove the screw and the tilt lever.
All columns
4. Remove the 3 screws and the upper and lower steering column shrouds.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Steering Column ................................................................................................................................................................. 211-04-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Steering Column

1 N806423 Steering column-to-instrument panel nuts (4 required)
2 N808684 Steering column shaft-to-steering column bolt
3 3E751 Upper steering column shaft
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)

4 7E395 Transmission selector lever cable
5 3C529 Steering column
6 — Transmission selector lever cable retainer (part of 7E395)
7 — Passive Anti-Theft System (PATS) transceiver electrical connector
(part of 14401)
8 — Brake shift interlock electrical connector housing (manual
transmission) (part of 14401)
9 — Brake shift interlock electrical connector (part of 14401)
10 — Overdrive cancel switch electrical connector (part of 14401)
11 — Multifunction switch electrical connector (part of 14401)
12 — Ignition switch electrical connector (part of 14401)
13 — Clockspring electrical connector (part of 14401)
14 — Wiring harness retainer (part of 14401)
15 — Wiring harness retainer (part of 14401)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
All vehicles
1. Remove the steering column shrouds. For additional information, refer to Steering Column Shroud in this section.
2. Remove the steering wheel. For additional information, refer to Steering Wheel in this section.
3. Remove and discard the upper steering column shaft-to-steering column bolt.
4. NOTE:
Vehicles with manual transmissions are not equipped with a brake shift interlock solenoid and have a plastic housing that retains the electrical
connector.
Disconnect the following electrical connectors.

• Clockspring
• Passive Anti-Theft System (PATS) transceiver
• Ignition switch
• Multifunction switch
• Brake shift interlock solenoid
Vehicles with column shift
5. Disconnect the overdrive cancel switch electrical connector.
6. Detach the transmission selector lever cable from the steering column and the bracket.
• Detach the transmission selector lever cable pin-type retainer.
All vehicles
7. Detach the wiring harness retainers from the steering column and position the wiring harness aside.
8. Detach the upper steering column shaft from the steering column.
9. Remove the 4 nuts and the steering column.
• Discard the nuts.
▪ To install, tighten the new nuts to 30 Nm (22 lb-ft).
10. NOTICE:
Make sure that the steering column support is flush with the instrument panel before tightening the nuts or damage to the steering column
may occur.
NOTICE:
Make sure the electrical wiring harness is routed correctly and secured to the steering column or damage to the wires and/or connectors may
occur.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Steering Wheel ................................................................................................................................................................... 211-04-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Steering Wheel

1 W709344 Steering wheel bolt
2 3600 Steering wheel

1. Remove the driver air bag module. For additional information, refer to Section 501-20B.
2. Turn the steering wheel to the straight-ahead position.
3. Remove and discard the steering wheel bolt.
4. Remove the steering wheel while routing the wires from the clockspring through the steering wheel.
5. Tape the clockspring center rotor to the outer housing to keep it from rotating.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
SPECIFICATIONS ..................................................................................................................................................................... 211-04-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

SPECIFICATIONS
Material
Premium Long-Life Grease ESA-M1C75-B —
XG-1-C or XG-1-K (US); CXG-1-C (Canada)

Ignition switch screw 5 — 44
Lower steering column shaft-to-steering gear bolt 35 26 —
Shifter assembly bolt and screws 6 — 53
Steering column shaft dash seal bolts 11 — 97
Steering column shroud screws 2 — 18
Steering column tilt housing screws 10 — 89
Steering column-to-instrument panel nuts 30 22 —
Steering wheel bolt 40 30 —
Steering wheel rotation sensor bolts 3 — 27
Tilt lever screw 6 — 53
Upper steering column housing position screw 25 18 —
Upper steering column shaft-to-lower steering column shaft bolt 48 35 —
Upper steering column shaft-to-steering column bolt 28 21 —
2008 F-250, 350, 450, 550 Super Duty, 7/2007

211-05-1 Steering Column Switches 211-05-1

Steering Column Switches Circuit Deactivation Ignition Module
(CDIM)
The steering column switches consist of the
following: Vehicles equipped with a 6.4L diesel engine may
also be equipped with a Circuit Deactivation
• Multifunction switch Ignition Module (CDIM), which is part of the
• Ignition switch engine idle shutdown system. The role of the
CDIM is to disconnect the ignition switch circuits
The steering column switches receive driver inputs
once the engine has shut down in order to prevent
and send signals to various components. The
possible battery drain. The engine idle shutdown
multifunction switch controls the windshield wipers,
system is controlled by the PCM, refer to the
hazard flasher, turn signal, headlamp low/high beam
Powertrain Control/Emissions Diagnosis (PC/ED)
and headlamp dimmer/flash-to-pass. The ignition
manual for information on the engine idle shutdown
switch is used in conjunction with the lock cylinder
system.
key to start the vehicle. When the lock cylinder key
is switched to different positions, it moves linkages
which enable the ignition switch to send battery
voltage to various components.


Steering Column Switches Multifunction Switch
The multifunction switch controls the various
Special Tool(s) components (high-beam headlamps, flash-to-pass,
Flex Probe Kit turn signal and windshield wiper) by grounding
105-R025D or equivalent certain Smart Junction Box (SJB) circuits and wiper
motor circuits. When the SJB detects the specific
ground, it sends a voltage to the appropriate
component to activate it. The SJB controls the
high-beam headlamps, the flash-to-pass and the turn
signals. The high-beam headlamp and the turn
Fluke 77-IV Digital Multimeter signal portion are normally open switches that close
FLU77-4 or equivalent when activated. The flash-to-pass switch is a
momentary contact switch that grounds the SJB
high-beam headlamp circuit. The windshield wipe
and wash functions are controlled directly by the
multifunction switch, wiper and washer motor.
Circuit Deactivation Ignition Module (CDIM)
Vehicle Communication Module
(VCM) and Integrated Vehicles equipped with a 6.4L engine may also be
Diagnostic System (IDS) equipped with an extended idle shutdown system.
software with appropriate The system is controlled by the PCM and uses
hardware or equivalent scan tool several inputs to determine whether or not to shut
the engine off. The function of the Circuit
Deactivation Ignition Module (CDIM) is to disable
the ignition circuits after the PCM has shut the
Principles of Operation engine off. For a complete description of the
extended idle shutdown system and the related
Ignition Switch
components, refer to Powertrain Control Software in
NOTE: The Smart Junction Box (SJB) is also the Powertrain Control/Emissions Diagnosis
identified as the Generic Electronic Module (GEM). (PC/ED) manual.
The ignition switch is controlled by the ignition Once the PCM has determined that the engine
lock cylinder with a key. When the ignition lock should be shut down, it sends a message to the
cylinder is turned using the key, a mechanical Instrument Cluster (IC) along the High Speed
connection positions the ignition switch to the Controller Area Network (HS-CAN) bus. The IC
selected position, and allows the ignition switch to then sends a message to the CDIM along the
send voltage to the Battery Junction Box (BJB) and Medium Speed Controller Area Network (MS-CAN)
the SJB. The ignition switch also contains a bus. Once the CDIM receives the message from the
key-in-ignition system that allows the SJB to detect IC, the CDIM will begin a 60 second timer and
when the key has been inserted in the ignition monitor the MS-CAN bus for ignition switch
switch. This information is used by the SJB for the position, brake pedal position and engine rpm. If the
brake shift interlock system. For information on the rpm remains at 0 and both the ignition switch and
brake shift interlock system, refer to Section brake pedal switch remain undisturbed for 60
307-05. The available ignition switch positions are: seconds, all CDIM internal relays will open and the
• OFF vehicle will enter into the standard accessory delay.
If 1 or more of the monitored signals changes
• ACC during the 60 second time period, the CDIM
• RUN internal relays will remain closed and allow voltage
• START to remain applied to the ignition circuits.

To reactivate the CDIM and ignition circuits after 4. NOTE: Make sure to use the latest scan tool
the engine shuts down and the 60 second time software release.
elapses, the ignition key must be turned to the OFF If the cause is not visually evident, connect the
position before attempting to start the engine or scan tool to the Data Link Connector (DLC).
before the key is turned to any other position.
5. NOTE: The Vehicle Communication Module
If the vehicle is getting the extended idle shut down (VCM) LED prove out confirms power and
system and the CDIM installed at a dealership as ground from the DLC are provided to the
opposed to the assembly plant, the PCM must be VCM.
enabled. To enable the PCM for extended idle
shutdown, refer to the Extended Idle Shutdown If the scan tool does not communicate with the
Initialization General Procedure in Section 303-14B. VCM:
• check the VCM connection to the vehicle.
Inspection and Verification
• check the scan tool connection to the VCM.
1. Verify the customer concern by operating the
• refer to Section 418-00, No Power To The
multifunction switch or ignition switch.
Scan Tool, to diagnose no power to the scan
2. Visually inspect for obvious signs of tool.
mechanical or electrical damage.
6. If the scan tool does not communicate with the
Visual Inspection Chart vehicle:
Mechanical Electrical • verify the ignition key is in the ON position.
• Multifunction switch • Battery Junction Box • verify the scan tool operation with a known
• Ignition switch (BJB) fuse(s): good vehicle.
• Key efforts — 40 (30A) • refer to Section 418-00 to diagnose no
• Steering column shrouds — 46 (40A)
• Circuit Deactivation response from the PCM.
Ignition Module 7. Carry out the network test.
(CDIM)
• Instrument Cluster (IC) • If the scan tool responds with no
• Passive Anti-Theft communication for one or more modules,
System (PATS) module refer to Section 418-00.
• Smart Junction Box
(SJB) fuse(s): • If the network test passes, retrieve and
— 25 (10A) record continuous memory DTCs.
— 26 (10A) 8. Clear the continuous DTCs and carry out the
— 27 (20A)
— 28 (5A) self-test diagnostics for the SJB and the CDIM.
— 42 (10A) 9. If the DTCs retrieved are related to the concern,
— 43 (10A) refer to the Smart Junction Box (SJB) DTC
— 44 (10A) Chart or the Circuit Deactivation Ignition
— 45 (5A)
• Wiring, terminals or Module (CDIM) DTC Chart. For all other
connectors DTCs, refer to Section 419-10.
10. If no DTCs related to the concern are retrieved,
3. If an obvious cause for an observed or reported GO to Symptom Chart.
concern is found, correct the cause (if possible) DTC Charts
before proceeding to the next step.
Smart Junction Box (SJB) DTC Chart
DTC Description Action
B2A20 Ignition Stuck in START GO to Pinpoint Test E.
B2844 Ignition Fault GO to Pinpoint Test F.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Smart Junction Box (SJB) DTC Chart (Continued)
U2472 Unexpected Ignition State GO to Pinpoint Test F.
All other DTCs — REFER the Master DTC Chart in Section
419-10.
Circuit Deactivation Ignition Module (CDIM) DTC Chart

B1342 ECU is Faulted INSTALL a new CDIM. REFER to Circuit
Deactivation Ignition Module (CDIM) in this
section.
B1355 Ignition Run Circuit Failure GO to Pinpoint Test G.
B1359 Ignition Run/Acc Circuit Failure GO to Pinpoint Test G.
B2477 Module Configuration Failure CLEAR the DTC. CARRY OUT the self-test.
RETRIEVE and RECORD any DTCs. If DTC
B2477 returns, INSTALL a new CDIM. REFER
to Circuit Deactivation Ignition Module
(CDIM) in this section.
U2050 No Application Present CLEAR the DTC. CARRY OUT the self-test.
RETRIEVE and RECORD any DTCs. If DTC
U2050 returns, INSTALL a new CDIM. REFER
to Circuit Deactivation Ignition Module
(CDIM) in this section.
Symptom Chart
Symptom Chart
• No power in all ignition • Fuse(s) • GO to Pinpoint Test A.
switch positions • Wiring, terminals or
connectors
• Ignition switch
• SJB
• Circuit Deactivation Ignition
Module (CDIM)
• No power in ACC • Fuse(s): • GO to Pinpoint Test B.
— 43 (10A)
— 45 (5A)
• Wiring, terminals or
connectors
• Ignition switch
• SJB
• No power in RUN • Fuse(s) • GO to Pinpoint Test C.
connectors
• Run/start relay
• Ignition switch
• SJB
• CDIM
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Symptom Chart (Continued)
• No power in START • Fuse(s) • GO to Pinpoint Test D.
connectors
• Starter motor relay
• Ignition switch
• SJB
• The ignition key is hard to • Key • GO to the Ignition Switch —
turn • Ignition lock cylinder Mechanical Component Test
• Ignition switch rod in this section.
• Ignition switch
• The multifunction switch does • Multifunction switch • CARRY OUT the
not operate correctly Multifunction Switch
Continuity Test for electrical
diagnosis. Refer to Wiring
Diagrams Cell 149 for
component testing.
Pinpoint Tests Normal Operation — Vehicles equipped with

a CDIM
Pinpoint Test A: No Power in All Ignition The ignition switch and the CDIM work together to
Switch Positions distribute fused battery voltage to the SJB, BJB,
Refer to Wiring Diagrams Cell 13, Power run/start relay and starter relay depending on the
Distribution/SJB for schematic and connector current ignition switch position. When the ignition
information. switch is placed in the ACC or START position, the
CDIM is in a passive state allowing the voltage to
Normal Operation — Vehicles not equipped
simply pass through the module using
with a Circuit Deactivation Ignition Module
(CDIM) normally-closed relays. When the ignition switch is
The ignition switch distributes fused battery voltage placed in the RUN position the CDIM becomes
to the Smart Junction Box (SJB), Battery Junction active. While active, the CDIM will still allow
Box (BJB), run/start relay and starter relay ignition voltage to pass through the internal relays,
depending on the current ignition switch position. but it will also start monitoring the Medium Speed
The ignition switch receives fused battery voltage Controller Area Network (MS-CAN) bus for
from SJB fuse 27 (20A) along circuit SBP27 messages. Once the voltage passes through the
(BU/RD). The ignition switch has 4 positions: CDIM, it returns to the ignition switch and then
out to various systems depending on ignition switch
• OFF — Power on circuit CDC30 (BU/GY) to the position. The ignition switch has 4 positions:
SJB for key-in ignition chime
• OFF — Power on circuit CDC30 (BU/GY) to the
• ACC — Power on circuit CDC33 (VT/GN) SJB for key-in ignition chime
• RUN — Power on circuits CDC32 (BN/YE), • ACC — Power on circuit CDC33 (VT/GN)
CDC33 (VT/GN) and CDC34 (WH/OG)
• RUN — Power on circuits CDC32 (BN/YE),
• START — Power on circuit CDC35 (BU/WH) CDC33 (VT/GN), CDC34 (WH/OG) and CDC63
and CDC34 (WH/OG) (YE/OG)
• START — Power on circuit CDC35 (BU/WH)
and CDC34 (WH/OG)
the following:
• Fuse
• Wiring, terminals or connectors
2008 F-250, 350, 450, 550 Super Duty, 7/2007

• Ignition switch
• SJB
• CDIM
PINPOINT TEST A: NO POWER IN ALL IGNITION SWITCH POSITIONS
NOTICE: Use the Flex Probe Kit for all test connections to prevent damage to the wiring
terminals. Do not use standard multi-meter probes.
A1 CHECK THE IGNITION SWITCH
• Carry out the Ignition Switch Component Test. Refer to Wiring Yes
Diagrams Cell 149 for component testing. GO to A2.
• Is the ignition switch OK? No
INSTALL a new ignition switch. REFER to
Ignition Switch in this section. TEST the
system for normal operation.
A2 CHECK VEHICLE EQUIPMENT
• Verify that the vehicle is equipped with a CDIM. Yes
• Is the vehicle equipped with a CDIM? GO to A3.
No
GO to A8.
A3 ISOLATE THE CDIM
• Disconnect: CDIM C2500.
• Connect a fused jumper wire between:
— CDIM C2500-1, circuit CDC63 (YE/OG), harness side and
CDIM C2500-8, circuit CDC32 (BN/YE), harness side.
— CDIM C2500-7, circuit SBP27 (BU/RD), harness side and
CDIM C2500-14, circuit CDC62 (WH/VT), harness side.
• Check for power in all ignition switch positions:

— Turn the ignition switch to the ACC position and operate the
radio, windshield wipers or blower motor.
— Turn the ignition switch to the RUN position and operate the Yes
radio, windshield wipers or blower motor. GO to A4.
— Start the engine. No
• Is power present in all ignition switch positions? GO to A5.
A4 CHECK THE CDIM GROUND CIRCUIT GD133 (BK) FOR AN
OPEN
• Ignition OFF.
(Continued)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

PINPOINT TEST A: NO POWER IN ALL IGNITION SWITCH POSITIONS (Continued)
A4 CHECK THE CDIM GROUND CIRCUIT GD133 (BK) FOR AN
OPEN (Continued)
• Measure the resistance between CDIM C2500-11, circuit GD133
(BK), harness side and ground.
Yes
GO to A5.
No
REPAIR circuit GD133 (BK). TEST the
• Is the resistance less than 5 ohms? system for normal operation.
A5 CHECK FOR VOLTAGE TO THE IGNITION SWITCH AND CDIM
• Ignition OFF.
• Disconnect: Ignition Switch C250.
• Measure the voltage between ignition switch C250-8, circuit
SBP27 (BU/RD), harness side and ground.
• Measure the voltage between CDIM C2500-7, circuit SBP27

(BU/RD), harness side and ground.
Yes
GO to A6.
No
VERIFY SJB fuse 27 (20A) is OK. If OK,
REPAIR circuit SBP27 (BU/RD). If not OK,
REFER to the Wiring Diagrams Manual to
identify the possible causes of the short
circuit. REPAIR as necessary. TEST the
• Are the voltages greater than 10 volts? system for normal operation.
(Continued)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

A6 CHECK CIRCUIT CDC62 (WH/VT) FOR AN OPEN
• Measure the resistance between CDIM C2500-14, circuit CDC62
(WH/VT), harness side and ignition switch C250-9, circuit
CDC62 (WH/VT), harness side and ground.
Yes
GO to A7.
No
REPAIR circuit CDC62 (WH/VT). TEST
• Is the resistance less than 5 ohms? the system for normal operation.
A7 CHECK THE IGNITION AND CDIM CIRCUITS FOR AN OPEN
• Disconnect: SJB C2280A.
• Disconnect: SJB C2280B.
• Disconnect: PCM C1232B.
• Disconnect: One-Touch Integrated Start (OTIS).
• Disconnect: Run/Start Relay.
• Measure the resistance between ignition switch C250-1, circuit
CDC34 (WH/OG), harness side and SJB C2280B-45, circuit
CDC34 (WH/OG), harness side.

CDC33 (VT/GN), harness side and SJB C2280A-3, circuit
CDC33 (VT/GN), harness side.
(Continued)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
CDC34 (WH/OG), harness side and run/start relay cavity 85,
circuit CDC34 (WH/OG), harness side.

CDC35 (BU/WH), harness side and PCM C1232B-26, circuit
CDC35 (BU/WH), harness side.
(Continued)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
(BN/YE), harness side and SJB C2280A-4, circuit CDC32
(BN/YE), harness side.
Yes
GO to A11.
No
REPAIR the affected circuit(s). TEST the
• Are the resistances less than 5 ohms? system for normal operation.
A8 CHECK FOR VOLTAGE TO THE IGNITION SWITCH
• Ignition OFF.
• Measure the voltage between ground and:
— ignition switch C250-8, circuit SBP27 (BU/RD), harness
side.
— ignition switch C250-9, circuit SBP27 (BU/RD), harness
side.
Yes
GO to A9.
No
VERIFY SJB fuse 27 (20A) is OK. If OK,
REPAIR circuit SBP27 (BU/RD). If not OK,
identify the possible causes of the short
• Is the voltage greater than 10 volts? system for normal operation.
A9 CHECK THE IGNITION CIRCUITS FOR AN OPEN
• Disconnect: SJB C2280A (all vehicles).
• Disconnect: SJB C2280B (all vehicles).
• Disconnect: SJB C2280E (diesel without OTIS).
• Disconnect: PCM C1232B (diesel with OTIS).
• Disconnect: PCM C175T (gasoline only).
• Disconnect: Run/Start Relay (all vehicles).
• For all vehicles, measure the resistance between the ignition
switch connector and the SJB connectors using the following
table:
(Continued)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

A9 CHECK THE IGNITION CIRCUITS FOR AN OPEN (Continued)
Ignition Switch Circuit SJB

C250-1 CDC34 (WH/OG) C2280B-45
C250-5 CDC33 (VT/GN) C2280A-3
C250-7 CDC32 (BN/YE) C2280A-4
C250-10a CDC35 (BU/WH)/ C2280E-8
CDC38 (WH/VT)
a For diesel engine vehicles without OTIS.
• For all vehicles, measure the resistance between ignition switch
C250-1, circuit CDC34 (WH/OG), harness side and run/start
relay cavity 85, circuit CDC34 (WH/OG), harness side.
(Continued)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

A9 CHECK THE IGNITION CIRCUITS FOR AN OPEN (Continued)
• For gasoline engine vehicles, measure the resistance between
ignition switch C250-10, circuit CDC35 (BU/WH), harness side
and PCM C175T-44, circuit CDC35 (BU/WH), harness side.
• For diesel engine vehicles, measure the resistance between

and PCM C1232B-26, circuit CDC35 (BU/WH), harness side.
Yes
GO to A10.
No
A10 CHECK THE SJB CONNECTORS
• Check SJB connectors C2280A, C2280B and C2280E (diesel
without OTIS) for:
— corrosion.
— pushed-out pins.
— spread terminals.
• Connect: SJB C2280A (all vehicles).
• Connect: SJB C2280B (all vehicles).
• Connect: SJB C2280E (all vehicles). Yes
• Connect: PCM C1232B (diesel only). INSTALL a new SJB. REFER to Section
• Connect: PCM C175T (gasoline only). 419-10. TEST the system for normal
• Connect: Ignition Switch C250 (all vehicles). operation.
• Connect: Run/Start Relay (all vehicles). No
• Make sure the connectors are seated correctly, then operate the The system is operating correctly at this
system and verify the concern is still present. time. Concern may have been caused by
• Is the concern still present? a loose or corroded connector.
A11 CHECK THE SJB CONNECTORS
• Check SJB connectors C2280A and C2280B for:
— corrosion.
• Connect: SJB C2280A.
(Continued)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

A11 CHECK THE SJB CONNECTORS (Continued)
• Connect: SJB C2280B.
• Connect: PCM C1232B. Yes
• Connect: OTIS Diode. INSTALL a new SJB. REFER to Section
• Connect: Run/Start Relay. 419-10. TEST the system for normal
• Connect: Ignition Switch C250. operation.
• Connect: CDIM C2500. No
Pinpoint Test B: No Power in ACC This pinpoint test is intended to diagnose

the following:
Refer to Wiring Diagrams Cell 13, Power
Distribution/SJB for schematic and connector • Wiring, terminals or connectors
information. • Ignition switch
Normal Operation • SJB
When the ignition switch is placed in the ACC
position fused ignition voltage is sent to Smart
Junction Box (SJB) fuse 43 (10A), 45 (5A) and the
internal logic of the SJB for ACC circuit
monitoring.
PINPOINT TEST B: NO POWER IN ACC
B1 CHECK THE IGNITION SWITCH
Diagrams Cell 149 for component testing. GO to B2.
B2 CHECK CIRCUIT CDC33 (VT/GN) FOR AN OPEN
• Ignition OFF.
Yes
GO to B3.
No
REPAIR circuit CDC33 (VT/GN). TEST the
(Continued)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

PINPOINT TEST B: NO POWER IN ACC (Continued)
B3 CHECK THE SJB CONNECTORS
• Check SJB C2208A for: Yes
— corrosion. INSTALL a new SJB. REFER to Section
— pushed-out pins. 419-10. TEST the system for normal
— spread terminals. operation.
• Connect: SJB C2208A. No
• Make sure the connector is seated correctly, then operate the The system is operating correctly at this
Pinpoint Test C: No Power in RUN • the CDIM.

Refer to Wiring Diagrams Cell 13, Power • SJB fuse 42 (10A) after passing through the
Distribution/SJB for schematic and connector CDIM.
information. • SJB fuse 43 (10A).
Normal Operation — Vehicles not equipped • SJB fuse 44 (10A) after passing through the
with a Circuit Deactivation Ignition Module CDIM.
(CDIM)
When the ignition switch is placed in the RUN • SJB fuse 45 (5A).
position fused ignition voltage is sent to: This pinpoint test is intended to diagnose
the following:
• the control side of the run/start relay.
• the internal logic of the Smart Junction Box (SJB)
for RUN circuit monitoring. • Run/start relay
• SJB fuse 42 (10A). • Ignition switch
• SJB fuse 43 (10A). • CDIM
• SJB fuse 44 (10A). • SJB
• SJB fuse 45 (5A). • Battery Junction Box (BJB)
Normal Operation — Vehicles equipped with

a CDIM
When the ignition switch is placed in the RUN
position fused ignition voltage is sent to:
• the internal logic of the SJB for RUN circuit
monitoring.
PINPOINT TEST C: NO POWER IN RUN
C1 CHECK THE IGNITION SWITCH
Diagrams Cell 149 for component testing. GO to C2.
(Continued)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

PINPOINT TEST C: NO POWER IN RUN (Continued)
C2 CHECK VEHICLE EQUIPMENT
• Verify that the vehicle is equipped with a CDIM. Yes
• Is the vehicle equipped with a CDIM? GO to C3.
No
GO to C6.
C3 ISOLATE THE CDIM
• Connect a fused jumper wire between:
— CDIM C2500-1, circuit CDC63 (YE/OG), harness side and
CDIM C2500-8, circuit CDC32 (BN/YE), harness side.
— CDIM C2500-7, circuit SBP27 (BU/RD), harness side and
CDIM C2500-14, circuit CDC62 (WH/VT), harness side.
• Check for power with the ignition switch in the RUN position:
— Turn the ignition switch to the RUN position and operate the Yes
radio, windshield wipers or blower motor. GO to C4.
• Is power present with the ignition switch in the RUN No
position? GO to C5.
C4 CHECK THE CDIM GROUND CIRCUIT GD133 (BK) FOR AN
OPEN
• Ignition OFF.
• Measure the resistance between CDIM C2500-11, circuit GD133
(BK), harness side and ground.
Yes
GO to C5.
No
REPAIR circuit GD133 (BK). TEST the
C5 CHECK THE IGNITION AND CDIM RUN CIRCUITS FOR AN
OPEN
(Continued)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

OPEN (Continued)
CDC63 (YE/OG), harness side and CDIM C2500-1, circuit
CDC63 (YE/OG), harness side.


CDC33 (VT/OG), harness side and SJB C2280A-3, circuit
CDC33 (VT/OG), harness side.
(Continued)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

OPEN (Continued)
CDC34 (WH/OG), harness side and:
— SJB C2280B-45, circuit CDC34 (WH/OG), harness side.
— run/start relay cavity 85, circuit CDC34 (WH/OG), harness
side.
Yes
GO to C7.
No
C6 CHECK THE IGNITION RUN CIRCUITS FOR AN OPEN
CDC32 (BN/YE), harness side and SJB C2280A-4, circuit
CDC32 (BN/YE), harness side.
(Continued)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

C6 CHECK THE IGNITION RUN CIRCUITS FOR AN OPEN
(Continued)

CDC34 (WH/OG), harness side and:
— SJB C2280B-45, circuit CDC34 (WH/OG), harness side.
— run/start relay cavity 85, circuit CDC34 (WH/OG), harness
side.
Yes
GO to C7.
No
(Continued)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

C7 CHECK FOR VOLTAGE AT THE RUN/START RELAY
• Measure the voltage between run/start relay cavity 30 and
ground.
Yes
GO to C8.
No
VERIFY BJB fuse 46 (40A) is OK. If OK,
identify the possible causes of the open
If not OK, REFER to the Wiring Diagrams
Manual to identify the possible causes of
the short circuit. REPAIR as necessary.
• Is the voltage greater than 10 volts? TEST the system for normal operation.
(Continued)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

C8 CHECK CIRCUIT GD113 (BK/YE) FOR AN OPEN
• Measure the resistance between run/start relay cavity 86, circuit
GD113 (BK/YE) and ground.
Yes
GO to C9.
No
REPAIR circuit GD113 (BK/YE). TEST the
C9 CHECK THE RUN/START RELAY
• Carry out the Mini ISO Relay Component Test. Refer to Wiring Yes
Diagrams Cell 149 for component testing. GO to C10.
• Is the relay OK? No
INSTALL a new run/start relay. TEST the
C10 CHECK THE SJB CONNECTORS
• Check the connectors for:
— corrosion. Yes
— pushed-out pins. INSTALL a new SJB. REFER to Section
— spread terminals. 419-10. TEST the system for normal
• Connect: SJB C2280A. operation.
• Connect: SJB C2280B. No
Pinpoint Test D: No Power in START Normal Operation

Refer to Wiring Diagrams Cell 13, Power When the ignition switch is placed in the START
Distribution/SJB for schematic and connector position, fused ignition voltage is sent to:
information. • the control side of the run/start relay.
for RUN circuit monitoring.
2008 F-250, 350, 450, 550 Super Duty, 7/2007
• the SJB and starter relay (diesel engines without • Starter relay
One-Touch Integrated Start (OTIS)) • Ignition switch
• the PCM and OTIS diode (diesel engines with • SJB
OTIS and all gasoline engines)
• Battery Junction Box (BJB)
the following:
• Run/start relay
PINPOINT TEST D: NO POWER IN START
D1 CHECK THE IGNITION SWITCH
Diagrams Cell 149 for component testing. GO to D2.
D2 CHECK CIRCUIT CDC34 (WH/OG) FOR AN OPEN
• Ignition OFF.
(Continued)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

PINPOINT TEST D: NO POWER IN START (Continued)
D2 CHECK CIRCUIT CDC34 (WH/OG) FOR AN OPEN (Continued)
CDC34 (WH/OG) and run/start relay cavity 85, circuit CDC34
(WH/OG), harness side.
Yes
GO to D3.
No
REPAIR circuit CDC34 (WH/OG). TEST
• Are the resistances less than 5 ohms? the system for normal operation.
(Continued)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

D3 CHECK FOR VOLTAGE AT THE RUN/START RELAY
• Measure the voltage between run/start relay cavity 30 and
ground.
Yes
GO to D4.
No
VERIFY BJB fuse 46 (40A) is OK. If OK,
INSTALL a new BJB. TEST the system for
• Is the voltage greater than 10 volts? normal operation.
(Continued)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

D4 CHECK CIRCUIT GD113 (BK/YE) FOR AN OPEN
• Measure the resistance between run/start relay cavity 86, circuit
GD113 (BK/YE) and ground.
Yes
GO to D5.
No
REPAIR circuit GD113 (BK/YE). TEST the
D5 CHECK THE RUN/START RELAY
• Carry out the Mini ISO Relay Component Test. Refer to Wiring Yes
Diagrams Cell 149 for component testing. GO to D6.
• Is the relay OK? No
INSTALL a new relay. TEST the system
for normal operation.
D6 CHECK CIRCUIT CDC35 (BU/WH) FOR AN OPEN
• Disconnect: SJB C2280E (all engines).
• Disconnect: PCM C1332B (diesel with OTIS).
(Continued)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

D6 CHECK CIRCUIT CDC35 (BU/WH) FOR AN OPEN (Continued)
• For diesel engine vehicles, measure the resistance between
and SJB C1232B-26, circuit CDC35 (BU/WH), harness side.
• For gasoline engine vehicles, measure the resistance between

and PCM C175T-44, circuit CDC35 (BU/WH), harness side.
Yes
GO to D7.
No
REPAIR circuit CDC35 (BU/WH). TEST
• Is the resistance less than 5 ohms? the system for normal operation.
D7 CHECK THE SJB CONNECTOR
• Check SJB C2280B for: Yes
— corrosion. INSTALL a new SJB. REFER to Section
— pushed-out pins. 419-10. TEST the system for normal
— spread terminals. operation.
• Connect: SJB C2280B. No
• Make sure the connector is seated correctly, then operate the The system is operating correctly at this
Pinpoint Test E: DTC B2A20 — Ignition Normal Operation

Stuck in START The ignition switch is spring loaded to automatically
Refer to Wiring Diagrams Cell 13, Power return to the RUN position after being placed in the
Distribution/SJB for schematic and connector START position. When the ignition switch is placed
information. in START, fused ignition voltage is sent to:
for RUN circuit monitoring.
• the PCM and OTIS diode on diesel engines with
OTIS and on all gasoline engines.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

• B2A20 Ignition Stuck in START — The SJB the following:
continuously monitors the ignition switch state, if • Wiring, terminals or connectors
the SJB detects voltage on circuit CDC35
(BU/WH) or CDC38 (WH/VT) for more than 30 • Ignition switch
seconds, DTC B2A20 will be set. • SJB
PINPOINT TEST E: DTC B2A20 — IGNITION STUCK IN START
E1 CHECK THE IGNITION SWITCH MECHANICAL FUNCTION
• Inspect the ignition switch for mechanical function. Refer to the Yes
Component Test Ignition Switch — Mechanical in this section. GO to E2.
Ignition Switch in this section. CLEAR the
DTCs. REPEAT the self-test.
E2 CHECK THE IGNITION SWITCH FOR A SHORT
Diagrams Cell 149 for component testing. GO to E3.
E3 CHECK CIRCUIT CBP28 (GY/VT) FOR A SHORT TO VOLTAGE
• Connect: Ignition Switch C250.
• Disconnect: SJB Fuse 28 (5A).
• Ignition ON.
• Measure the voltage between SJB fuse 28 (5A), output side and
ground.
Yes
GO to E4.
No
• Is any voltage present? GO to E5.
E4 ISOLATE THE Audio Control Module (ACM)
• Ignition OFF.
• Disconnect: ACM C240A.
• Ignition ON.
(Continued)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

PINPOINT TEST E: DTC B2A20 — IGNITION STUCK IN START (Continued)
E4 ISOLATE THE Audio Control Module (ACM) (Continued)
• Measure the voltage between SJB fuse 28 (5A), output side and
ground.
Yes
REPAIR circuit CBP28 (GY/VT). CLEAR
the DTC. REPEAT the self-test.
No
INSTALL a new ACM. REFER to Section
415-00. CLEAR the DTCs. REPEAT the
• Is any voltage present? self-test.
E5 CHECK CIRCUITS CDC35 (BU/WH) AND CDC38 (WH/VT) FOR A
SHORT TO VOLTAGE
• Ignition OFF.
• Disconnect: PCM C1232B (diesel engine).
• Disconnect: PCM C175T (gasoline engine).
• Disconnect: Starter Relay.
• Disconnect: OTIS Diode.
• Ignition ON.
• Measure the voltage between SJB fuse 28 (5A), input side and
ground.
Yes
REPAIR circuit CDC35 (BU/WH) and/or
CDC38 (WH/VT). CLEAR the DTCs.
REPEAT the self-test.
No
E6 ISOLATE THE PCM
• Connect: PCM C1232B (diesel with OTIS).
• Connect: PCM C175T (gasoline engine).
(Continued)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

PINPOINT TEST E: DTC B2A20 — IGNITION STUCK IN START (Continued)
E6 ISOLATE THE PCM (Continued)
ground.
Yes
INSTALL a new PCM. REFER to Section
303-14A for gasoline engines and Section
303-14B for diesel engines. CLEAR the
No
E7 ISOLATE THE STARTER RELAY
• Connect: Starter Relay.
ground.
Yes
INSTALL a new starter relay. CLEAR the
No
E8 CHECK THE OTIS DIODE FOR A SHORT OR AN OPEN
• Check the diode. Yes
• Is the diode shorted or open? INSTALL a new OTIS diode. CLEAR the
No
GO to E9.
E9 CHECK THE SJB CONNECTORS
• Disconnect: SJB C2280E.
• Check SJB connectors C2280B and C2280E for:
— corrosion. Yes
— pushed-out pins. INSTALL a new SJB. REFER to Section
— spread terminals. 419-10. CLEAR the DTCs. REPEAT the
• Connect: SJB C2280B. self-test.
• Connect: SJB C2280E. No
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Pinpoint Test F: DTCs B2844 and U2472 — • U2472 Unexpected Ignition State — If during the
Ignition Fault and Unexpected Ignition State SJB self test, the ignition is not in the RUN
Refer to Wiring Diagrams Cell 13, Power position or the RUN position cannot be detected,
Distribution/SJB for schematic and connector DTC U2472 will be set.
information. This pinpoint test is intended to diagnose
the following:
Normal Operation
When placed in ACC, RUN or START, the ignition • Wiring, terminals or connectors
switch sends voltage out to the Smart Junction Box • Ignition switch
(SJB). Microprocessors in the SJB continuously
monitors the ignition switch state. • SJB
• B2844 Ignition Fault — If the SJB receives an

invalid ignition state (such as detecting voltage on
the START circuit when the switch is in the RUN
position) during normal operation, DTC B2844
will be set.
PINPOINT TEST F: DTCs B2844 AND U2472 — IGNITION FAULT AND UNEXPECTED IGNITION STATE
F1 CHECK THE IGNITION SWITCH
• Ignition OFF. Yes
• Carry out the Ignition Switch Component Test. Refer to Wiring For DTC U2472, GO to F2.
Diagrams Cell 149 for component testing. For DTC B2844, GO to F4.
• Is the ignition switch OK?
No
F2 CHECK CIRCUIT CDC33 (VT/GN) FOR AN OPEN
Yes
GO to F3.
No
REPAIR circuit CDC33 (VT/GN). CLEAR
• Is the resistance less than 5 ohms? the DTCs. REPEAT the self-test.
F3 CHECK CIRCUIT CDC34 (WH/OG) FOR AN OPEN
(Continued)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
F3 CHECK CIRCUIT CDC34 (WH/OG) FOR AN OPEN (Continued)
Yes
GO to F6.
No
REPAIR circuit CDC34 (WH/OG). CLEAR
F4 CHECK THE IGNITION CIRCUITS FOR A SHORT TO VOLTAGE
• Ignition OFF.
• Disconnect: One-Touch Integrated Start (OTIS) Diode.
• Disconnect: Ignition Switch C250 (all vehicles).
• Disconnect: SJB C2280A (all vehicles).
• Disconnect: SJB C2280B (all vehicles).
• Disconnect: SJB C2280E (all vehicles).
• Disconnect: PCM C1232B (diesel).
• Measure the voltage between ground and:
— SJB C2280A-3, circuit CDC33 (VT/GN), harness side. Yes
— SJB C2280A-4, circuit CDC32 (BN/YE), harness side. REPAIR the affected circuit(s). CLEAR the
— SJB C2280B-45, circuit CDC34 (WH/OG), harness side. DTCs. REPEAT the self-test.
— SJB C2280E-8, circuit CDC38 (WH/VT), harness side. No
• Is any voltage present? GO to F5.
F5 CHECK THE IGNITION CIRCUITS FOR AN OPEN
C250-1, circuit CDC34 (WH/OG), harness side and SJB
C2280B-45, circuit CDC34 (WH/OG), harness side.
(Continued)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
F5 CHECK THE IGNITION CIRCUITS FOR AN OPEN (Continued)
C250-5, circuit CDC33 (VT/GN), harness side and SJB
C2280A-3, circuit CDC33 (VT/GN), harness side.
• For diesel engine vehicles without OTIS, measure the

resistance between ignition switch C250-10, circuit CDC35
(BU/WH), harness side and SJB C2280E-8, circuit CDC38
(WH/VT), harness side.

CDC35 (BU/WH), harness side and the OTIS diode, input side.
(Continued)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
F5 CHECK THE IGNITION CIRCUITS FOR AN OPEN (Continued)
• Measure the resistance between OTIS diode, output side and
SJB C2280E-8, circuit CDC38 (WH/VT), harness side.
Yes
For vehicles equipped with OTIS, GO to
F6.
For vehicles not equipped with OTIS, GO
to F7.
No
REPAIR the affected circuit(s). CLEAR the
• Are the resistances less than 5 ohms? DTCs. REPEAT the self-test.
F6 CHECK THE OTIS DIODE FOR A SHORT OR AN OPEN
• NOTE: The diode should only have continuity in one direction. Yes
Using the diode setting on the Fluke 77-IV Digital Multimeter, GO to F7.
test the diode. No
• Is the diode OK? INSTALL a new OTIS diode. CLEAR the
F7 CHECK THE SJB CONNECTORS
• Check SJB connectors C2280A, C2280B and C2280E for:
— corrosion.
• Connect: SJB C2280A (all vehicles).
• Connect: SJB C2280B (all vehicles).
• Connect: SJB C2280E (all vehicles).
• Connect: PCM C1232B (diesel with OTIS). Yes
• Connect: PCM C175T (gasoline only). INSTALL a new SJB. REFER to Section
• Connect: Ignition Switch C250 (all vehicles). 419-10. CLEAR the DTCs. REPEAT the
• Connect: Run/Start Relay (all vehicles). self-test.
• Connect: OTIS Diode (diesel and all gasoline vehicles). No
Pinpoint Test G: DTCs B1355 and B1359 — Normal Operation

Ignition Run Circuit Failure and Ignition The Circuit Deactivation Ignition Module (CDIM)
Run/ACC Circuit Failure receives RUN circuit input from the ignition switch
Refer to Wiring Diagrams Cell 13, Power and provides a RUN/ACC output to the Smart
Distribution/SJB for schematic and connector Junction Box (SJB). The CDIM has
information. micro-processors that continually monitor these
inputs and outputs. If a circuit failure is detected,
the applicable DTC will be set.
• B1355 Ignition Run Circuit Failure — If the
CDIM determines that the input circuit from the
ignition switch is open or shorted to ground
during normal operation, DTC B1355 will be set.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

• B1359 Ignition Run/Acc Circuit Failure — If the the following:
CDIM determines that the output circuit to the • Wiring, terminals or connectors
SJB is open or shorted to ground during normal
operation, DTC B1359 will be set. • Ignition switch
• CDIM
PINPOINT TEST G: DTCs B1355 AND B1359 — IGNITION RUN CIRCUIT FAILURE AND IGNITION
RUN/ACC CIRCUIT FAILURE
G1 CHECK THE IGNITION SWITCH
• Ignition OFF. Yes
• Carry out the Ignition Switch Component Test. Refer to Wiring For DTC B1355, GO to G2.
Diagrams Cell 149 for component testing. For DTC B1359, GO to G4.
• Is the ignition switch OK?
No
DTCs . REPEAT the self-test.
G2 CHECK CIRCUIT CDC63 (YE/OG) FOR AN OPEN
CDC63 (YE/OG), harness side and CDIM C2500-1, circuit
CDC63 (YE/OG), harness side.
Yes
GO to G3.
No
REPAIR circuit CDC63 (YE/OG). CLEAR
G3 CHECK CIRCUIT CDC63 (YE/OG) FOR A SHORT TO GROUND
CDC63 (YE/OG), harness side and ground.
Yes
GO to G6.
No
REPAIR circuit CDC63 (YE/OG). CLEAR
• Is the resistance greater than 10,000 ohms? the DTCs. REPEAT the self-test.
(Continued)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

PINPOINT TEST G: DTCs B1355 AND B1359 — IGNITION RUN CIRCUIT FAILURE AND IGNITION
RUN/ACC CIRCUIT FAILURE (Continued)
G4 CHECK CIRCUIT CDC32 (BN/YE) FOR AN OPEN
• Ignition OFF.
Yes
GO to G5.
No
REPAIR circuit CDC32 (BN/YE). CLEAR
G5 CHECK CIRCUIT CDC32 (BN/YE) FOR A SHORT TO GROUND
(BN/YE), harness side and ground.
Yes
GO to G6.
No
REPAIR circuit CDC32 (BN/YE). CLEAR
• Is the resistance greater than 10,000 ohms? the DTCs. REPEAT the self-test.
G6 CHECK THE CDIM CONNECTORS
• Check the CDIM connector for: Yes
— corrosion. INSTALL a new CDIM. REFER to Circuit
— pushed-out pins. Deactivation Ignition Module (CDIM) in this
— spread terminals. section. CLEAR the DTCs. REPEAT the
• Connect: CDIM C2500. self-test.
• Make sure the connector seats correctly, then operate the No
system and verify the concern is still present. The system is operating correctly at this
• Is the concern still present? time. Concern may have been caused by
a loose or corroded connector.
Component Tests • Binding lock cylinder

Ignition Switch — Mechanical • Burrs or foreign material around the rack and
pinion actuator in the lock cylinder housing
The following conditions can cause difficulty in
operating the ignition switch and lock cylinder: • Insufficient lube on the actuator (Do not apply
lubricant to the inside of the ignition switch.)
• Burrs on the lock cylinder key
• Binding ignition switch
• Insufficient lube on the lock cylinder
2008 F-250, 350, 450, 550 Super Duty, 7/2007

If the steering wheel lock is engaged with the • If the ignition switch and lock cylinder do
wheels loaded against a curb, high effort will be not return from the START position back to
necessary to turn the key from lock. Turn the the RUN position without assistance,
steering wheel to either side of the lock to unload continue with Step 4.
the system. 4. Remove the ignition lock cylinder. Refer to
Perform the following test to determine if the Section 501-14.
ignition switch and lock cylinder are operating 5. Rotate the ignition lock cylinder through all of
correctly. the switch positions.
1. Inspect the ignition key for any burrs, damage • If the lock cylinder operates correctly,
or incorrect cut. Replace the ignition key as continue with Step 6.
necessary.
• If the lock cylinder does not operate
2. NOTE: The steering wheel may be locked full correctly, install a new ignition lock
left or full right. If the steering wheel is locked, cylinder. Refer to Section 501-14.
it will be necessary to apply turning effort to
the steering wheel in the direction of the lock 6. Check for binding or sticking ignition switch
while turning the key. actuating rod, burrs around the rack-and-pinion
actuator in the ignition lock cylinder housing or
Turn the key to the ACC position and then the insufficient lubrication.
RUN position.
• If there is sufficient lubrication and there are
• If the ignition key turns to the ACC and no burrs, binding or sticking conditions,
RUN position, continue with Step 3. install a new ignition switch. Refer to
• If the ignition key will not turn to the ACC Ignition Switch in this section.
and RUN position, continue with Step 4. • If there is insufficient lubrication, burrs,
3. NOTE: The ignition switch and lock cylinder binding or sticking conditions, repair or
should return from the START position back to lubricate as necessary.
the RUN position without assistance.
Ignition Switch — Electrical
Turn the ignition key to the START position
and release the key. Refer to Wiring Diagrams Cell 149 for component
testing.
• If the ignition switch and lock cylinder
return from the START position back to the Multifunction Switch — Electrical
RUN position without assistance, the Refer to Wiring Diagrams Cell 149 for component
ignition switch is operating correctly at this testing.
time.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


Circuit Deactivation Ignition Module
(CDIM)
Item Part Number Description Installation

1 W706350 Pin-type retainers (2 required)
2 — Circuit Deactivation Ignition 1. Connect the electrical connector.
Module (CDIM) electrical
connector (part of 14401) 2. Position the CDIM and install the 2 pin-type
3 12C527 CDIM retainers.
• If the CDIM is being installed new as a
Removal dealership option, the PCM must be enabled.
For additional information, refer to the
1. Remove the 2 pin-type retainers. Extended Idle Shutdown Initialization
General Procedure in Section 303-14B.
2. Remove the Circuit Deactivation Ignition
Module (CDIM) and disconnect the electrical
connector.


Ignition Switch
NOTE: Tilt column shown, fixed column similar.
Item Part Number Description Vehicles with tilt column

1 N802141 Ignition switch screw
2 11572 Ignition switch 3. Remove the steering column. For additional
All columns • Place the steering column on a clean
workbench.
1. Depower the Supplemental Restraint System
4. Position the column in the full upward position.
(SRS). For additional information, refer to
Section 501-20B.
Vehicles with fixed column
2. Remove the steering column shroud. For


5. Using suitable tools, push the first roll pin out 7. Position the tilt lever to rest against the steering
of the fixed shoe. column housing.
6. Pivoting on the second roll pin, tilt the fixed All columns
shoe downward.
8. Remove the ignition switch screw and the
ignition switch.
9. NOTICE: Make sure the electrical wiring

harness is routed correctly and secured to
the steering column or damage to the wires
and/or connectors may occur.
10. Repower the SRS. For additional information,

refer to Section 501-20B.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


Steering Column Multifunction Switch

1 78044F08 Steering column opening trim 5 — Tilt lever dust boot (part of
2 3530A Upper steering column shroud 3530B)
3 3530B Lower steering column 6 — Tilt lever screw (part of
shroud 3F609)
4 W710485 Lower steering column 7 3F609 Tilt lever
shroud screws (3 required) (Continued)
(Continued)

Item Part Number Description 2. Disconnect the multifunction switch electrical
8 — Multifunction switch connector.
electrical connector (part of
14401) 3. Remove the 2 screws and the multifunction
9 13K359 Multifunction switch switch.
10 W506943 Multifunction switch screw (2 • To install, tighten to 1 Nm (9 lb-in).
required)
1. Remove the steering column shroud. For

2008 F-250, 350, 450, 550 Super Duty, 7/2007

SPECIFICATIONS
Description Nm lb-in
Ignition switch screw 5 44
Multifunction switch screws 1 9
Tilt lever screw 6 53


Steering System

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Steering System

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211-00-1 Steering System 211-00-1

DESCRIPTION AND OPERATION

Copyright  2007, Ford Motor Company

DIAGNOSIS AND TESTING

Dial Thermometer 0-220°F Item Specification

Copyright  2007, Ford Motor Company

2008 F-250, 350, 450, 550 Super Duty, 7/2007

Symptom Chart — Steering System

Symptom Chart — Steering System

2008 F-250, 350, 450, 550 Super Duty, 7/2007

Symptom Chart — NVH

2008 F-250, 350, 450, 550 Super Duty, 7/2007

2008 F-250, 350, 450, 550 Super Duty, 7/2007

2008 F-250, 350, 450, 550 Super Duty, 7/2007

2008 F-250, 350, 450, 550 Super Duty, 7/2007

Pinpoint Tests This pinpoint test is intended to diagnose

• NOTICE: Do not hold the steering wheel at the stops for an

2008 F-250, 350, 450, 550 Super Duty, 7/2007

• NOTICE: Do not hold the steering wheel at the stops for an

Pinpoint Test C: Excessive Steering Wheel

2008 F-250, 350, 450, 550 Super Duty, 7/2007

Pinpoint Test D: Steering System the following:

2008 F-250, 350, 450, 550 Super Duty, 7/2007

2008 F-250, 350, 450, 550 Super Duty, 7/2007

2008 F-250, 350, 450, 550 Super Duty, 7/2007

4. Have an assistant grasp the tire and move the

2008 F-250, 350, 450, 550 Super Duty, 7/2007

Fill Adapter Manifold, Power

Vacuum Pump Kit

Copyright  2007, Ford Motor Company

Item Description 3. NOTE: The Power Steering Fill Adapter

2008 F-250, 350, 450, 550 Super Duty, 7/2007

18. Install the reservoir cap.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

Copyright  2007, Ford Motor Company

Copyright  2007, Ford Motor Company

Vacuum Pump Kit

5. Using the Vacuum Pump Kit, apply vacuum

3. Tightly insert the Power Steering Evacuation

Copyright  2007, Ford Motor Company

14. Stop the engine, release the vacuum and

15. NOTE: Do not overfill the reservoir.

16. Visually inspect the power steering system for

2008 F-250, 350, 450, 550 Super Duty, 7/2007

9. NOTE: The on-center torque must be 1.01-1.47

Vehicles with 6.4L diesel

10. Remove the upper cooling fan shroud. For

Copyright  2007, Ford Motor Company

11. NOTE: Rotate the meshload screw clockwise

12. Verify that the on center torque is to

13. Hold the meshload screw and tighten the

Vehicles with 6.4L diesel

15. Install the upper cooling fan shroud. For

16. Install the driver air bag. For additional

2008 F-250, 350, 450, 550 Super Duty, 7/2007

SECTION 211-02 Power Steering

Power Steering Fluid Reservoir .......................................................................................................................................... 211-02-2

2008 F-250, 350, 450, 550 Super Duty, 7/2007

Power Steering Fluid Reservoir

Item Part Number Description

2008 F-250, 350, 450, 550 Super Duty, 7/2007

Remove the 2 power steering fluid reservoir bolts.

2008 F-250, 350, 450, 550 Super Duty, 7/2007