Section 99 (Power Steering System): Pulley: Installation

WARNING: This page is about a different car, the 2004 Dodge Pickup and 2004 Dodge Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: Do not reuse the old power steering pump pulley it is not intended for reuse. A new pulley must be installed if removed.

Replace the pulley if it's bent, cracked, or loose.
Install the pulley on the pump using (OTC® 7771) power steering pulley installation tool or equivalent (Fig 1) making sure it is flush with the end of the shaft. Ensure the tool and pulley remain aligned with the pump shaft.

Fig 1: Installing Pulley
Courtesy of DAIMLERCHRYSLER CORP.
Install the power steering pump assembly, (Refer to PUMP ).
Run engine until warm (5 min.) and note any belt chirp. If chirp exists, move pulley outward approximately 0.5 mm (0.020 in.). If noise increases, press on 1.0 mm (0.040 in.). Be careful that pulley does not contact mounting bolts.

Replace pulley if bent, cracked, or loose.
Install pulley on pump with Installer C-4063-B (Fig 1) flush with the end of the shaft. Ensure the tool and pulley remain aligned with the pump shaft.

Fig 1: Installing Pulley
Courtesy of DAIMLERCHRYSLER CORP.
Install pump assembly.
With Serpentine Belts; Run engine until warm (5 min.) and note any belt chirp. If chirp exists, move pulley outward approximately 0.5 mm (0.020 in.). If noise increases, press on 1.0 mm (0.040 in.). Be careful that pulley does not contact mounting bolts.