Power Steering Pump Pulley

Remove and replace the power steering pump pulley on a 2008 Dodge Viper 8.4L V10, requiring pulley puller and installer tools to separate and reinstall the press-fit pulley.

Warnings

Tools required

Parts

• Power steering pump pulley × 1 — Use OEM specification
• Serpentine drive belt (if damaged) × 1 — Use OEM specification

Fluids

• power_steering — 1.5 qt

Preparation

1. Park vehicle on level ground and set parking brake
2. Disconnect negative battery cable to prevent accidental engine start
3. Allow engine to cool if recently operated to reduce burn risk
4. Place drain pan beneath power steering pump area to catch fluid spillage

Procedure

1. 1

   Remove serpentine drive belt
   Locate the serpentine belt tensioner on the front of the engine. Using a 3/8" drive ratchet or serpentine belt tool, rotate the tensioner in the direction that unloads the spring (verify against the underhood belt routing decal) to release tension on the belt. Slip the belt off the power steering pump pulley first, then carefully release tensioner and remove belt from remaining pulleys. Inspect belt for cracks, glazing, or fraying and replace if worn.
2. 2

   Access power steering pump
   The power steering pump is located on the driver side front of the engine. Verify clear access to the pump pulley from above. On the Viper, the pump is typically accessible without removing additional components, though you may need to work around heater hoses and AC lines in the area.
3. 3

   Drain power steering fluid (optional but recommended)
   To minimize fluid loss and mess, disconnect the power steering return hose (lower hose) from the pump using a line wrench or standard wrench. Allow fluid to drain into the drain pan. You can also disconnect the pressure line, but this requires more cleanup. If you choose not to drain, be prepared for significant fluid spillage when removing the pulley.
4. 4

   Install pulley puller tool
   Position the power steering pulley puller so the center bolt bears against the end of the pump shaft and the puller jaws grip behind the pulley (verify whether this pump shaft accepts a threaded center bolt or requires a jaw-type puller). Position the puller's legs or arms behind the pulley, ensuring they grip the back face of the pulley securely. Verify the puller is centered and seated properly to avoid damage to the pulley or pump housing.
5. 5

   Remove pulley from pump shaft
   Using a wrench or ratchet, turn the center bolt of the pulley puller clockwise. This will draw the pulley off the pump shaft. Apply steady, even pressure. The pulley will gradually pull free from the press-fit shaft. Once free, remove the puller tool and pulley together, then separate them.
6. 6

   Inspect pump shaft and pulley
   Examine the pump shaft for scoring, burrs, or damage. Light surface rust or discoloration is normal. Clean the shaft with a shop towel. Inspect the old pulley hub bore for signs of wear or cracking. Verify the new pulley matches the old pulley in diameter, offset, and hub depth.
7. 7

   Install new pulley onto pump shaft
   Place the new pulley onto the pump shaft, ensuring it is properly aligned and seated flush against the shaft shoulder. Position the power steering pulley installer tool over the pulley and pump shaft. The installer tool typically uses the pump mounting bolt holes or a threaded shaft adapter to press the pulley onto the shaft. Thread the installer's drive bolt and tighten gradually, pressing the pulley onto the shaft until it is fully seated and flush with the pump shaft shoulder. Do not force or impact the pulley.
8. 8

   Verify pulley installation
   Remove the installer tool. Check that the pulley is fully seated with no gap between the pulley hub and the pump shaft shoulder. The pulley should not wobble or have any lateral play. Spin the pulley by hand to verify it rotates freely without binding.
9. 9

   Reconnect power steering lines
   If you disconnected the return hose or pressure line, reconnect them now. For the pressure line, ensure the fitting is clean and torque to the factory-specified value for the high-pressure line fitting. For the return hose, tighten the hose clamp securely. Wipe away any residual fluid from the pump and surrounding components.
10. 10

    Reinstall serpentine drive belt
    Route the serpentine belt around all pulleys according to the belt routing diagram (typically found on a decal under the hood or in the owner's manual). Save the power steering pump pulley for last. Rotate the belt tensioner clockwise to create slack, slip the belt onto the power steering pump pulley, then release the tensioner to apply proper tension. Verify the belt is seated correctly in all pulley grooves.
11. 11

    Refill and bleed power steering system
    Fill the power steering reservoir with Mopar ATF+4 fluid to the cold fill line (verify total system capacity against factory service specifications). Reconnect the negative battery cable. Start the engine and turn the steering wheel slowly from lock to lock several times while idling. Check the fluid level and add as needed. Continue turning the wheel until no air bubbles appear in the reservoir and the fluid level stabilizes. Top off fluid to the hot fill line once the system is at operating temperature.

Reassembly

1. Serpentine belt installation mirrors removal: rotate tensioner, route belt, verify proper seating in all pulley grooves
2. Power steering lines reconnect in reverse order of removal: pressure line first (if removed), then return hose with clamp tightened securely
3. Negative battery cable reconnects last after all mechanical work is complete

Verification

• Start engine and verify no abnormal noise from power steering pump or pulley area
• Turn steering wheel from lock to lock while idling and verify smooth operation with no whining, binding, or excessive noise
• Check for power steering fluid leaks around pump, hoses, and connections
• Verify serpentine belt tracks properly on all pulleys without slipping or chirping
• Confirm power steering reservoir fluid level is at the hot fill line after system reaches operating temperature
• Test drive vehicle and verify normal power steering assist at low speeds and no unusual noises

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