2002 Grand Marquis LSE!

[mercurygm88]

I was able to remove the bolt from the rear of the solenoid, I then removed the internal siding valve and spring. Everything has been back to normal since then.

[sly]

You need a strap wrench to get that solenoid out. It's normal thread, but usually too damn tight to remove normally. Also need to clean every bit a fluid from the outside of the inner part of that solenoid before you can get it out with said strap wrench. Also high possibility of destroying that end if it collapses in on itself getting it out. They may also locktite that in so heat may be required. Not sure about that one though. I know it's f'n tight. That's where my last one failed. The inner seals on the EVO solenoid. I could not get it out either.

As for a quick fix... start the car... tap on the solenoid to try to get it to release. Move the wheel back and forth... tappy tap tap again... if it doesn't work after 5 attempts... I'd swap pumps. As for the police/taxi pump... as long as it has the same fittings, it should work, but you WILL need to use the PTFE washer on the high pressure line. I use a tall skinny funnel to slowly heat and expand that to get it over the threads as I don't have the cone tool that's used to slide it over the threads. Those are single use sealing washers. An o-ring will not work.

[mercurygm88]

It appears that removing that Allen bolt just allows disassembly of the solenoid. There doesn't seem to be a way to get the solenoid body out of the pump. Anyone know a quick fix to get this back on the road? I have the solenoid unplugged but it's apparently stuck internally.

Edit: I did some more research. It appears that the OEM EVO solenoid is 1 piece and comes out when you remove the hex screw. The aftermarket pumps use a multiple piece EVO solenoid and the body does not unscrew from the pump housing. If I put the Police/Taxi pump on the car with the non Police/Taxi gear box will that cause any issues? It's either that or leave the EVO solenoid disconnected and hope it frees up again. I don't trust putting another EVO pump on it since I'm assuming the EVO/RAS module is my issue considering both systems are acting up.

[mercurygm88]

Does anyone know if the bolt holding the EVO solenoid on is right or left hand thread? I'm trying to get the new one off of the reman pump and it's way tighter than I would think it should be.

[mercurygm88]

Thanks Sly. I’ll take a good look at those when I get the chance. I dropped the glove box and there’s one module with two connectors that says EVO/RAS. I tried reseating the connectors, that didn’t trick it into working.

If I can just trick the EVO solenoid into freeing up again I can just unplug it for now. I don’t know what to do on the air suspension side of things as I was unable to find the exact part number anywhere online

It looks like my price for a new power steering pump with the EVO solenoid is cheaper than buying just the solenoid online. I think I’m going to try that and I’ll just keep the spare power steering pump in case I ever need it.

As for the air suspension I guess I’ll have to live with it as is unless sometime down the road I can find this exact module. I’ll probably post a WTB thread for one in the next few days.

[sly]

Here's the RAS troubleshooting: http://www.grandmarq.net/sly/2002%20...leshooting.pdf
Here's the EVO troubleshooting: http://www.grandmarq.net/sly/2002%20...leshooting.pdf

[sly]

The module can be swapped out. That said... check the wiring to it first to make sure it's not just losing contact with power. Not sure on the availability of the module though. Yes, the module is located behind the glove box. It has two wire harnesses going to it. Checked my service manual.

Edit: Actually, there may be two modules. I'm going to post the RAS troubleshooting from the service manual shortly. Probably one box with two connectors. Mind the diagrams to figure out which one is which.

[mercurygm88]

I just got home from work and as I was pulling in the driveway the car bogged down like it was going to stall and now the steering is sticking again. I’m guessing this has to be EVO related.

Edit: I read over on CVN that the EVO/RAS is all in one module above or behind the glove compartment. I'm thinking this could be causing both of my issues, can this module simply be swapped out and if so is it easily available?

[mercurygm88]

I hiked the EVO solenoid back up and drove about 15 miles. The steering is like new and far better than it’s been in the two years I’ve owned the car. I guess I’m not going to worry about it as long as it continues to cooperate.

[mercurygm88]

As strange as it sounds as of today the steering is back to normal. I think it has something to do with me unhooking the EVO solenoid the other night.

I realize when the EVO fails it’s supposed to default to full assist but I think mine was stuck the opposite way and now that it’s been unhooked for a few days it’s gone back to normal.

I honestly can’t think of any other explanation. I’ll keep an eye in it and I’ll be ordering a new EVO solenoid payday.

[mercurygm88]

I'll have to see what I can find for the steering shafts and do those next.

[Mainemantom]

"That sticking issue sounds like the intermediate and possibly upper steering shafts are shot. The U-joints in the lower shaft get cooked from the exhaust manifold heat and bind up, which puts more strain on the upper shaft and firewall bearing"

I agree with the above. Plus rust gets in there You should be able to find NOS parts. You might even see if those steering shafts are covered under a recall. I replaced both of shafts on the 96 Mine were binding almost solid in one direction. After new shafts and a "Red Top" steering box, steering is like new.

[VicCrownVic]

Must be steering component day. I changed the idler arm today on the '98, bushing was shot.
I'll keep an eye out for a decent rear bumper cover. I need one myself so I'm already looking, but mine is not quite that bad. Just paint (Bondo?) cracking and a missing paint chip a little smaller than a dime. (The Rear bumper was trashed in the dealer pics I found of my car before it made its way to the used car lot I got it from.)

[FordMan77]

That sticking issue sounds like the intermediate and possibly upper steering shafts are shot. The U-joints in the lower shaft get cooked from the exhaust manifold heat and bind up, which puts more strain on the upper shaft and firewall bearing. I just went through this on my 03. Replaced both shafts and the firewall bearing and it steers nice and smooth again. I was actaully able to source OEM Ford ones so they're out there. Also note that the pinch bolt is stated as one time use. I wasn't willing to risk it so I replaced it too.

[mercurygm88]

Installed a new Pitman arm tonight. The old one was totally shot. That was a huge pain in the ass both nuts came off easy with my 1/2” impact. The impact did nothing on the pitman arm puller, I ended up using a 6’ section of 1” I.D. pipe on the ratchet handle, I can’t believe neither the $10 Chinesium puller or cheap no name “Made in Taiwan” ratchet didn’t disintegrste. I didn’t want to I use one of my good ratchets just in case.

Got it back together, steering is nice and tight but the wheel still sticks every 1/4 turn or so and won’t return on its own when you turn I’m guessing the steering box is shot? Seems odd at only 120,000 miles.

Also I went on about a 30 mile drive and the air suspension light came on again! I don’t know what the hell is going on. It’s almost like after a pre determined time “about 20 minutes” The light comes on. The car sat for a month recently and the rear never sagged so I don’t think it’s a leak. Do the height sensors on these ever act up and just not read?