Power Steering Pump Pulley

Remove and replace the power steering pump pulley on a 2005 Dodge Viper 8.3L V10. Requires pulley removal and installation tools to safely press the pulley on and off the pump shaft.

Warnings

Tools required

Parts

• Power steering pump pulley × 1 — Use OEM specification
• Power steering pressure line O-ring × 1 — Use OEM specification
• Power steering return line O-ring × 1 — Use OEM specification
• ATF+4 automatic transmission fluid × 2 — Mopar ATF+4 or equivalent

Fluids

• ATF+4 — 1.5 qt

Preparation

1. Ensure engine is cold and vehicle is parked on level ground
2. Disconnect negative battery cable
3. Place drain pan beneath power steering pump area
4. Have shop towels ready for fluid cleanup

Procedure

1. 1

   Remove serpentine drive belt
   Locate the belt tensioner on the front of the engine. Using a breaker bar or serpentine belt tool, rotate the tensioner in the direction that releases tension on the belt (verify direction against the service manual/routing decal). Slip the belt off the power steering pump pulley first, then release tensioner and remove belt from remaining pulleys. Slip the belt off the power steering pump pulley first, then release tensioner and remove belt from remaining pulleys. Note belt routing for reinstallation.
2. 2

   Drain power steering fluid
   Position drain pan directly under the power steering pump. Using line wrenches to prevent rounding, disconnect the pressure line fitting from the pump. Allow fluid to drain into pan. Disconnect the return line from the pump. Cap or plug the open lines to prevent additional fluid loss and contamination.
3. 3

   Install pulley puller tool
   Position the power steering pulley puller so its center bolt bears against the end of the pump shaft. Ensure the puller jaws or arms are positioned evenly behind the pulley face, engaging the pulley securely. Verify the tool is centered on the shaft before proceeding.
4. 4

   Remove pulley from pump shaft
   Gradually tighten the center bolt of the puller tool, which will press against the pump shaft and pull the pulley off. Apply steady, even pressure. The pulley will separate from the shaft with resistance. Once free, remove the puller tool and pulley together.
5. 5

   Inspect pump shaft and new pulley
   Examine the pump shaft for damage, burrs, or debris. Clean the shaft with a clean shop towel if needed. Inspect the new pulley bore for any obstructions or manufacturing defects. Verify the new pulley matches the original in diameter and offset.
6. 6

   Install new pulley using installer tool
   Position the new pulley onto the pump shaft, aligning it squarely. Place the pulley installer tool over the pulley and thread it into the pump shaft (or use the appropriate adapter for your tool design). The installer presses on the pulley hub, not the pulley face. Gradually tighten the tool to press the pulley onto the shaft until it is fully seated. The pulley should be flush with the shaft end or positioned at the same depth as the original pulley was installed.
7. 7

   Reconnect power steering lines
   Install new O-rings on both the pressure line and return line fittings, lubricating lightly with ATF+4. Thread the pressure line fitting into the pump by hand first to ensure proper alignment, then torque to the factory-specified value (verify in service manual). Connect the return line (note: this may be a hose/clamp connection rather than a torqued fitting) and secure per factory specification. Ensure both fittings are properly seated and not cross-threaded.
   Torque spec

   Pressure Line Fitting34 Nm (25 lb-ft)
8. 8

   Reinstall serpentine belt
   Route the serpentine belt according to the belt routing diagram (typically found on a decal under the hood or in the service manual). Ensure the belt is properly seated in all pulley grooves. Rotate the tensioner clockwise again and slip the belt onto the final pulley, then release tensioner to apply proper tension.
9. 9

   Refill power steering system
   Locate the power steering fluid reservoir. Fill with ATF+4 fluid to the cold fill line or as marked on the reservoir. Start the engine and turn the steering wheel slowly lock-to-lock 5-10 times to circulate fluid and purge air from the system. Check fluid level and top off as needed. Inspect for leaks at pump fittings.
10. 10

    Verify system operation and check for leaks
    With engine running, verify smooth power steering operation with no unusual noises (groaning, whining, or squealing may indicate air in system or low fluid). Turn steering wheel through full range of motion several times. Shut off engine and inspect all connection points at the pump for leaks. Recheck fluid level after test and top off if necessary.

Reassembly

1. Reconnect negative battery cable after all work is complete
2. Dispose of used power steering fluid according to local environmental regulations
3. Recheck power steering fluid level after first drive and top off if needed
4. Monitor for leaks during first 50 miles of operation

Verification

• Power steering operates smoothly without noise or binding
• No fluid leaks present at pump line connections
• Serpentine belt tracks properly on all pulleys without misalignment
• Power steering fluid level remains stable at proper mark
• New pulley rotates smoothly without wobble or vibration

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