Power steering leak

Ive got a 99 windstar with a ps fluid leak. it seems to be coming from the bolt/plug on the rear of the steering rack, could it be as simple as a seal? I recently topped off the reservior, im thinking I couldve over filled it. Marc

First you have to determine from where exactly is leaking. From the rack area could be more than seal leaking. If the inside seal is leaking then you should find steering fluid in the rubber boots (doesn’t matter which side as the fluid will circulate from one to the other through the breathing tube). In case you find fluid in the boots the rack & pinion need to be replaced. If not then you should start looking on the top valve seal, the one close to the column steering…try to dry up the place first then start the engine and turn steering in both sides and check again….if it’s wet than again the rack should be replaced. In case that it’s not leaking from there then start checking the pressure and return line….
It’s interesting to know if you have other symptoms like: lack of power steering, noise in the pump (caused by lower level of fluid), shuddering, etc.
Try to find first the leaking cause.:evillol:

Thanks for the reply,
What I found was if im under the vehicle looking towards the front I can see the rack, im looking at the back of it and there is a bolt or plug the size of a Quarter almost in the middle. my leak is coming from that bolt/plug. as the fluid gets lower I get the groaning pump sound but it goes away when i fill it up again. Marc

Is very hard from your description to locate the leaking. It could be from one of the lines that goes to the housing (there are two lines and one is close to the middle and the other one close to the right end - passanger side).The plug that you say it's leaking it's from one of the pressure lines that goes from the valve to the body of the rack. Try to use a key to tide up the bolt and see if it's still leaking. From the Valve body (the vertical part of the housing that is connecting with the steering column) are two pipes (lines) that each of them sending pressure to the cylinder of the rack. Those pipes are threaded in so you can try tide them up....if it's still leaking than you have to change the line...I don't know if you can find the line on aftermarket but that is the problem and it's not worth it to buy an other rack. Although, all garages will just change the rack. Maybe you can take th eline from scrap...make sure you change the teflon o-ring before re-install the line. These lines have a teflon o-ring (plastic ) and if the thread is not damaged then should work.
Windstar rack housing is from aluminum and easy to damage threads...if the thread is damages you have to change the rack. If you buy from aftermarket a rack I suggest two rebuilders that are top on North America market and cheaper than New OEM Ford rack, and that should be Cardone or Fenco.
Make sure if you buy yourself the rack and try to install it that you let me know to give you some tips......

Hi, dragos69ca -

I'm in the middle of installing a new rack on my 99 windstar 3.8L. If you can help, I would be grateful.

On the instructions included with the new rack, they make reference to a "flow valve" and "valve stopper". They say I need to remove these from the old rack and install them on the new rack. HOWEVER, I don't even see these parts on the old rack. Failure to use the flow valve and valve stopper will "cause a steering system malfunction and void the warranty"

I have a pic if it helps... http://members.cox.net/tdschubert/DSC01773.JPG.

Thanks and Best Rgds...

Yes...the Installation Notice that you have is from a rack from Fenwick Automotive (Fenco)...as you can see in the picture, you have on the rack the ports for pressure and return line that are coming from the steering pump. In the pressure port of the old unit you'll find this small vlave...the retainer will keep this valve in place. You will notice that the return port has a bigger hole than the pressure port. BE CAREFUL AS BOTH PORTS HAVE THE SAME THREAD SIZE AND IF YOU SWITCH THE LINES AT INSTALLATION YOU'LL DAMAGE THE SEALS AND LEAKS. First you remove the retainer ring and after that the valve can get out easy. Some times when installers are removing the old unit from the car they don't pay attention and they loose this valve (the retainer probably is not in place and valve is loose and fall down). If the valve is not in the pressure port then you can have low pressure in the system and noise in the parking manouvers.
If you don't have the valve then you can try to buy it from a Ford Dealer.
Very Important: before removing the lines note which one was pressure lines so you know when you install it on the new rack.
Let me know if you have other problems...most of the Ford installers make this mistake of switching the lines and after leaking you have to get a new unit again.