I’ve got a 1999 F-150. The front seal on the power steering pump was leaking, so I removed the pump and used a pulley puller to remove the pulley from the leaking pump. When I try to install the pulley on the new pump, I just can’t get the pulley flush with end of the shaft. The pulley is about a 1/8 of an inch from being flush. I keep shearing the grade 8.8 bolts or striping the threads on the bolt or nuts. I even chilled the pump in the freezer and put the pulley in 150 degree F oven. Any suggestions on how to get the pulley flush with the shaft?

Dave

 

I measured the shaft of the pump and the hole in the pulley and found that the shaft was almost .030 larger than the pulley hole. I ended up boring out the pulley hole to the same size as the shaft (I went back to the parts dealer and checked the shaft size and they varied as much as .080 of an inch). Just to be on the "safe" side I also used a set bolt in the end of the shaft to ensure that the pulley would not spin off.

 

Tsquared - Thanks for the advice.

Well, I got the end of pulley flush with the shaft. It was the hard way. I took the pulley and pump back to the parts store and they tried to pull the pulley onto the shaft using their specialty tool. It wouldn’t budge. They said that it was too tight, and they volunteered to remove the pulley for me. Well, the parts guy gouged the inside of the pulley when he removed it. I used my Dremel to sand it smooth. I went a little too far and the pulley went on with just hand pressure. So, I cleaned the shaft and the inside of the pulley with some acetone and put a little JB Weld on inside of the pulley. I put it together and put a bolt and washer on the pulley/shaft to make sure it lined up correctly. I installed the pump and now I am waiting for the 15 hours for the JB to cure. I’ll give it a try tomorrow and see what happens.

As I was waiting, the guy at the counter said that they pull and install pulleys all the time for their customers. I should have asked! Oh well, live and learn the hard way.

Dave