Power Steering Removal Difficulties

[arian]

Hey all,

Just bought a '95 Astro, AWD, 180k miles; I got it for a killer deal, but with that, a few problems to take care of. My first series of jobs include the water pump, front breaks, and the power steering pump.
So I've picked up everything I need, got to the pump, took it off the bracket, but I can't get enough clearance to get to the hoses in the back. I've seen that removing the bracket seems to make everything easier, but my bracket doesn't match up with newer models (with the 4 bolts and a nut) so I want to make sure I do this correctly. I attached an image of the bracket. The blue bolts seem to be the ones holding the ac compressor to the bracket. Do I just need to remove the six bolts and hang the compressor with a bungee?
I've scoured through the forum and other resources but can't quite get the information I need, so any tips regarding the issue at hand, other jobs, or general advice regarding the van is welcomed and well appreciated.

Thanks

[AstroWill]

Do I just need to remove the six bolts and hang the compressor with a bungee?

Yes, remove the bolts for the AC compressor, but don't disconnect the lines at all. That will allow you to move the bracket and get enough room for the rest.

[arian]

Awesome, I believe I saw you say the same thing in another post, thank you for the clarification. Those top two bolts facing towards the engine look like they’re going to be a pain.

[arian]

Yes, remove the bolts for the AC compressor, but don't disconnect the lines at all. That will allow you to move the bracket and get enough room for the rest.

Hey Will, want to thank you for your help here and on my other post as well. I'm having some trouble with my serpentine belt now that I've gotten everything back together. It pops off whenever I try to start the car. My best guess is that my power steering pump pulley does not seem to be aligned with everything else. I've removed the pulley from the pump and have tried to remount it, but it still seems to sit a little too far forward and the pulley won't go any further in. Do you have any suggestions? Thanks

[AstroWill]

Hmm, have a picture of how it sits right now? One from top down and one of the front of the pulley would be great.

[Mmusicman]

Yes.. if the PS pulley is not seated correctly, it will likely throw the belt.
Of course, it is assumed the bracket is mounted square on the block.

Last time I did mine.. I used a straight-edge/square to be certain it all lined up.

[arian]

Yes.. if the PS pulley is not seated correctly, it will likely throw the belt.
Of course, it is assumed the bracket is mounted square on the block.

Last time I did mine.. I used a straight-edge/square to be certain it all lined up.

Hmm, have a picture of how it sits right now? One from top down and one of the front of the pulley would be great.

Planning on doing some further investigation today, I'll take some pictures. I've reinstalled the pulley a few times, I don't think its a seating issue at this point. The block is worth looking into, I did make sure to tighten all the bolts evenly so it sits flush, hopefully that isn't the issue. I've read that the pulley shaft could be a different length (compared to the original), I'm going to take measurements there. If that's the issue I'm thinking of adding washers between the pump and bracket to align the pulley.

[AstroWill]

Shaft length doesn't matter as long as you can hit the spot where everything is in alignment. It's designed so that there can be some adjustment, can't just put it flush with the shaft and call it good.

[arian]

Shaft length doesn't matter as long as you can hit the spot where everything is in alignment. It's designed so that there can be some adjustment, can't just put it flush with the shaft and call it good.

AC to PS

AC to PS, pulleys look to be in line here

Fan to PS

Crankshaft vs PS

Looks like the PS pulley is too far forward

Idler Pulley

When I start the car with the belt installed, the belt slips off the idler pulley.

Belt Tensioner to AC

Hard to tell if the belt tensioner and AC pulleys are out of line. My best guess is that the PS pulley or the bracket is the issue. The thing that throws me off is that the belt is coming off the idler pulley. Since the AC and PS seem to be lined up, I'd guess that the whole bracket is too far forward, but after sticking my phone in the nooks and crannies around the bracket, there doesn't really look like there is any room for it to move back.

[Mmusicman]

You can't just go by visual...
It's needs to be aligned with a straight edge/square or something equivalent and precise.
Of course measuring technique will greatly affect results.

Have you simply tried to drive the pulley further on?
Is that a gap in your last photo?
Could something be causing the bracket to not be installed properly?

[arian]

You can't just go by visual...
It's needs to be aligned with a straight edge/square or something equivalent and precise.
Of course measuring technique will greatly affect results.

Have you simply tried to drive the pulley further on?

I would measure, but the PS pulley is just so far forward its obvious and the pulley won't go any further.

[Mmusicman]

Is that a gap in your last photo?

[arian]

Is that a gap in your last photo?

From the bracket to the block, yes; but, it's less than a few mm and it looks like the points where the bolts meet the block are flush.

[CarpeDiem]

Watch for an errant washer...that got me once.
I've got to do a PS pump change come spring, so I have been listening with interest.
Let us know how it progresses.

[AstroWill]

That pulley is way forward, why will it not go deeper on the shaft?

[WinnieVan]

How are you installing the pulley? With an install tool? That PS pulley needs to go WAY further down to get into alignment -- at least based on the picture of the alignment with the crank pulley.

Are you certain you got the right part? Did your new PS pump come with a new pulley?

[arian]

How are you installing the pulley? With an install tool? That PS pulley needs to go WAY further down to get into alignment -- at least based on the picture of the alignment with the crank pulley.

Are you certain you got the right part? Did your new PS pump come with a new pulley?

I'm using an install tool. Its the pump my local shop said would fit, rock auto carries the same one under 95 Astro.https://www.rockauto.com/en/moreinfo.php?pk=7045888&cc=1028067&jsn=2936

It didn't come with a new pulley, maybe I should try a new one? Worst case I get the same result and return it.

That pulley is way forward, why will it not go deeper on the shaft?

I've tried removing and re-installing the pulley a few times now, that just as far as it seems to want to go.

[AstroWill]

But is the pulley bottoming out, or are you just putting it on until it's flush with the end of the shaft?

[arian]

But is the pulley bottoming out, or are you just putting it on until it's flush with the end of the shaft?

I'm going until the pulley bottoms out, which at that point is not flush with the end of the shaft. I just removed the pulley and measured the shaft with a caliper. It looks like the new pumps shaft is 3mm longer than the original.

[AstroWill]

In that case it sounds like maybe they had the correct box but the wrong pump. Never had one that wouldn't line up.

All three front pump bolts in properly?