Complete removal and replacement of the power steering pump on a 1966 Chevrolet Corvette 327ci V8, including drive belt, pulley, pressure and return lines, and system bleeding.

Warnings

Tools required

Parts

• Power steering pump × 1 — Use OEM specification or quality aftermarket equivalent
• Power steering pump pulley (if not transferring from old pump) × 1 — Use OEM specification
• High pressure line O-rings × 2 — Use OEM specification
• Pressure line O-rings × 2 — Use OEM specification
• Drive belt (if worn or damaged) × 1 — Use OEM specification for 327 V8 with power steering

Fluids

• GM Power Steering Fluid — 1 qt

Preparation

1. Park vehicle on level surface and set parking brake
2. Allow engine to cool completely if recently operated
3. Disconnect negative battery cable to prevent accidental starter engagement
4. Place drain pan under power steering pump area
5. Clean external surfaces of pump, lines, and mounting area to prevent contamination

Procedure

1. 1

   Relieve system pressure and drain fluid
   Start the engine and turn the steering wheel fully from lock to lock 2 times to warm the fluid. Shut off engine. Using a turkey baster or fluid transfer pump, remove as much power steering fluid as possible from the reservoir. This will minimize spillage during line removal.
2. 2

   Remove drive belt
   Loosen the power steering pump mounting bolts to create slack in the belt. The 1966 327 V8 uses an adjustable pump bracket without a tensioner. Loosen the front pump mounting bolt and the rear adjusting bracket bolt, then push the pump toward the engine block. Slip the belt off the pump pulley, then off the crankshaft pulley.
3. 3

   Disconnect high pressure hose
   Position drain pan directly under the high pressure line fitting at the pump. Using a flare nut wrench, loosen and remove the high pressure hose fitting from the pump discharge port. Expect fluid drainage. Plug or cap the hose end immediately to prevent contamination. Discard the old O-rings from the fitting.
   Torque spec

   High Pressure Hose Fitting25 Nm (18 lb-ft)
4. 4

   Disconnect return hose
   Locate the low pressure return hose connected to the reservoir return fitting (the connection secured with a hose clamp). Using hose clamp pliers or a flat blade screwdriver, loosen the return hose clamp. Twist and pull the return hose off the pump inlet fitting. Drain remaining fluid into the pan. Plug the hose end to prevent contamination.
   Torque spec

   Return Hose Clamp3 Nm (2 lb-ft)
5. 5

   Remove pump mounting bolts
   Remove the bolts securing the power steering pump and its mounting/adjusting bracket to the engine. Verify the exact bolt count and configuration against the factory service manual, as the Saginaw pump uses a pivot mount plus an adjusting bracket. Support the pump as you remove the final bolt.
   Torque spec

   Power Steering Pump Bolts25 Nm (18 lb-ft)
6. 6

   Remove pump from vehicle
   Carefully maneuver the power steering pump out from its mounting location. The pump will still contain residual fluid, so keep the drain pan positioned underneath. Tilt the pump to drain any remaining fluid from the reservoir and internal passages.
7. 7

   Remove pulley from old pump (if transferring)
   If transferring the pulley to the new pump, secure the pump in a vise with soft jaws. Install the power steering pulley puller tool onto the pulley. Tighten the puller center bolt while holding the pulley stationary until the pulley releases from the pump shaft. Note the pulley orientation and depth on the shaft for reinstallation reference.
8. 8

   Install pulley on new pump
   Clean the pump shaft on the new pump with a wire brush. Align the pulley onto the shaft in the same orientation as removed. Using a pulley installation tool or carefully driving the pulley with a large socket that contacts only the pulley hub (never the outer rim), press the pulley onto the shaft until it reaches the same depth as the original pump. The pulley hub should be flush with the end of the shaft.
9. 9

   Install new pump to mounting bracket
   Position the new power steering pump into the mounting bracket on the engine block. Install the front mounting bolt and the rear adjusting bracket bolt finger-tight. Do not fully tighten yet, as the pump must be adjusted for belt tension.
10. 10

    Connect return hose
    Slide the return hose onto the pump inlet fitting, ensuring it is fully seated. Position a new hose clamp (or reuse the original if in good condition) and tighten to the specified torque. Ensure the hose is routed without kinks or interference.
    Torque spec

    Return Hose Clamp3 Nm (2 lb-ft)
11. 11

    Connect high pressure line
    Verify the high pressure fitting sealing method for this pump; the Saginaw pressure line typically uses an inverted-flare tube seat (no O-ring). If an O-ring is used, install a new one lightly lubricated with clean fluid. Thread the fitting into the pump discharge port by hand to avoid cross-threading. Once seated, torque the fitting to specification using a flare nut wrench while holding the pump body steady.
    Torque spec

    High Pressure Hose Fitting25 Nm (18 lb-ft)
12. 12

    Install and tension drive belt
    Route the drive belt over the crankshaft pulley and power steering pump pulley. Using a pry bar against the pump body (on a reinforced section, not the reservoir), lever the pump away from the engine block to create belt tension. Belt deflection should be 1/2 inch with firm thumb pressure at the longest span between pulleys. While holding tension, torque the front mounting bolt and rear adjusting bracket bolt to specification.
    Torque spec

    Power Steering Pump Bolts25 Nm (18 lb-ft)
13. 13

    Fill and bleed power steering system
    Fill the power steering reservoir to the FULL COLD mark with the specified fluid (1966 Saginaw systems use Type A / Dexron automatic transmission fluid). With the engine off, turn the steering wheel slowly from lock to lock 10 times to purge air from the system. Check fluid level and top off as needed. Start the engine and let it idle. Turn the wheel slowly from lock to lock 5 times, pausing briefly at each lock position. Check for leaks at all connections. Stop the engine, recheck fluid level, and top off to the FULL HOT mark. Restart and verify smooth operation without noise or binding.

Reassembly

1. Verify all hose clamps and fittings are tightened to specification
2. Confirm drive belt is properly tensioned and aligned on all pulleys
3. Check power steering fluid level after system bleeding
4. Reconnect negative battery cable

Verification

• Start engine and verify no leaks at pump connections, pressure line, or return hose
• Turn steering wheel lock to lock with engine running and verify smooth operation without whining, groaning, or binding
• Check that power steering fluid level remains at FULL HOT mark after test drive
• Verify belt is not slipping or making noise during steering input
• Test drive vehicle and confirm normal steering assist at idle and all speeds

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