[mikesta]

Hi Guys,

New here and don't know if this is the right place to post.

I am trying to fix a PS pump for a friend that is scraping by after being layed off. 4 kids etc....

I spent 9 hours yesterday trying to replace his PS pump.

The Shaft Sheered off and the pulley/shaft came out so I was able to access the bolts and quickly take the pump off and get the pump back in.
Because I didn't follow the FSM (dont have one) out of frustration, went to the web and found this proceedure for a 2000 Safari. I don't know if its the same.

I think the harmonic ballencer needs to be removed to get to the fan.

Anyways 5 hours of cranking the nut and only 3/4 of the way there. Any assistance would be so helpfull..... I'd kiss you virtually (and I'm a manly man) thats how desperate I am to get this vehicle going for this friend.

Tools Required
• Power Steering Pump Pulley Remover
• Power Steering Pump Pulley Installer
Remove the upper fan shroud.
Remove the fan.
Remove the lower fan shroud.
Remove the air conditioning compressor.
Notice: Do not hammer the pulley off the shaft. The pulley or the pump may be damaged.
Remove the power steering pump pulley as follows:
Install thepower steering pulley remover .
Hold the nut .
Turn the pilot bolt clockwise .
Remove the power steering pump mounting bolts and the nut.
Place a drain pan under the power steering pump.
Important: Cap or plug the ends of the power steering hoses to prevent fluid loss.
Disconnect the power steering hoses from the pump.
Remove the power steering pump.

Installation Procedure

Install the power steering pump.
Uncap the ends of the power steering hoses and install the hoses to the rear of the pump.
Install the power steering pump mounting bolts and the nut .
Tighten

• Tighten the power steering mounting bolts to 50 N·m (37 lb ft).
• Tighten the power steering nut to 41 N·m (30 lb ft).
Notice: Do not hammer the pulley onto the shaft. The pulley or the pump may be damaged.
Install the power steering pump pulley as follows:
Place the pulley on the end of the pump shaft.
Install the power steering pulley installer. Ensure that the pilot bolt is bottomed in the shaft.
Hold the pilot bolt .
Turn the nut clockwise until the pulley is seated.
Install the air conditioning compressor..
Install the lower fan shroud.
Install the fan.
Install the upper fan shroud.
Fill the power steering reservoir with power steering fluid to the COLD/FULL mark.
Bleed the power steering system.
Inspect the power steering hoses for the following:
- Leaks
- Proper clearance

I Hope this helps
Pawl

 

[astro355]

Welcome to the site. Yes, you can swear at any vehicle. Its a lot cheaper to swear at the van instead of breaking something else on it. Can you get a picture of the problem area? What you listed looks right for the pump removal. It would help to see what you are looking at.

 

[Matrixx]

Hi mikesta
Welcome aboard, everything is straightforward "except" installing the pulley onto the pump shaft. What I had to do is gently and slowly heat the pulley up at the whole (200 degrees fahrenheit max), add a bit of grease to the inside of it and got the pulley to start on the shaft by hand. Only then, do you use the pulley installer from that point on. Once the pulley has started on the shaft, the shaft itself must be made "flush" with the front side of the pulley give or take .25mm (.01 inch).
Here is a link that may help, it's for a 96 and the only difference I believe is the electrical Plug-in you may have at the back of the pump, mine doesn't have that (96).
http://www.autozone.com/az/cds/en_us/09 ... oPages.htm
Hope this helps.

PS: No, the harmonic balancer does not get removed for this particular application. To remove the Clutch Fan from the pump, you need something to hold the water pump in place and use a large wrench or crescent wrench that fits over the large nut behind the fan and turn the nut itself "counter clockwise" to break it loose.

 

[mikesta]

Very cool guys. Thanks for the response.

We got it.... After the washer that came with the kit exploded we put another washer on it (thin) and all our cranking last night just made the washer concave.
Went to schucks to get a beefier pulley assembly tool (they didn't have on) and they said to use a tougher washer.

I had a couple frame washers (from the 5 FJ60 landcruisers I've parted) and used one of those with a grade 10.5 metric nut purchased from schucks with. (6 points of contact instead of the square nut proved with the kit). Well that one stripped the nut threads within 3 turns.

Put the square nut back on with 1 Frame washer and after 30 minutes had it pressed on.

That was by far the toughest Power steering pump I've ever done.

I'm still cursing because at the kit they provided... the washer literally shattered into 6 equal pieces. Thankfully the square Nut came through!

Thanks again!

 

[Matrixx]

Hi mikesta
I'm glad to see you made some headway with it. Yes, it can be tough to do for sure (mine was). 30 minutes? wow, you beat me by an hour and a half,hehe. Good job.

 

[mikesta]

Hi mikesta
I'm glad to see you made some headway with it. Yes, it can be tough to do for sure (mine was). 30 minutes? wow, you beat me by an hour and a half,hehe. Good job.

That was 30 minutes of cranking teh last 1/4 on... hehe... I think you got me beat... total time was 13 hours.

 

[Matrixx]

13 hrs ??....Oooh...hmm....Well I might have you beat by a few minutes their, yeh... At least it's done...Good work mikesta.

 

[astro355]

Sounds like you guys should do the V8 swap. Power steering pump R&R on my van is 20 minutes, total. :banana:

 

[Matrixx]

Hi astro355
20 Minutes? Wow, That is good for a pump Re&Re. It takes 20 minutes just to get access to mine.

 

[astro355]

I'll have to take a pic of the area (sorry, I don't have one already) so you can see how much room I have.