Power Steering Pump Pulley

Remove and replace the power steering pump pulley on a 1972 Ford F-100 with 302ci V8 engine using a pulley removal and installation tool.

Warnings

Tools required

Parts

• Power steering pump pulley × 1 — Use OEM specification or aftermarket equivalent
• Power steering pressure line O-ring (if equipped) × 1 — Use OEM specification

Fluids

• Type F ATF — 0.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Allow engine to cool completely if recently operated
3. Disconnect negative battery cable to prevent accidental engine start
4. Place drain pan under power steering pump area

Procedure

1. 1

   Relieve belt tension and remove drive belt
   Locate the alternator pivot bolt and adjustment bolt. Loosen the alternator adjustment bolt and pivot bolt to create slack in the drive belt. Remove the drive belt from the power steering pump pulley. Note the belt routing for reinstallation.
2. 2

   Access power steering pump pulley
   Inspect the pulley for access. The pulley can typically be accessed with the pump installed on the engine. Verify there is adequate clearance to position the pulley puller tool on the pulley. If access is restricted by hoses or brackets, proceed to step 3. If access is clear, proceed to step 4.
3. 3

   Remove obstructing components if necessary
   If required for tool access, disconnect the power steering pressure line from the pump using a flare nut wrench. Cap the line immediately to prevent fluid loss and contamination. Remove the return hose from the pump reservoir and cap both hose and reservoir fitting. Note the orientation of any brackets that must be removed for access.
   ⚠Type F ATF will drain from disconnected lines. Keep drain pan positioned to catch fluid.
4. 4

   Install pulley removal tool
   Position the power steering pulley puller tool onto the pulley. The tool consists of a thrust bearing plate that sits behind the pulley and a pulling screw that threads into the center hole of the pulley. Thread the center screw of the puller tool; the screw will bear against the pump shaft (most pumps from this era do not have internally threaded shafts - the puller applies force by bearing against the shaft end). Ensure the pulling arms are seated evenly behind the pulley face and the thrust plate is centered on the shaft.
5. 5

   Remove pulley from pump shaft
   Using a wrench on the center screw of the puller tool, turn clockwise to draw the pulley off the pump shaft. Apply steady, even pressure. The pulley will release from the press-fit taper on the shaft. Continue turning until the pulley is completely free from the shaft. Remove the puller tool and pulley together, then separate. Verified detail (The pump shaft on a Ford/Saginaw power steering pump is a straight press-fit, not a tapered fit. Describing it as a taper is factually incorrect and could confuse the operator.): Using a wrench on the center screw of the puller tool, turn clockwise to draw the pulley off the pump shaft. Apply steady, even pressure. The pulley will release from the press-fit on the shaft. Continue turning until the pulley is completely free from the shaft. Remove the puller tool and pulley together, then separate.
6. 6

   Inspect pump shaft and pulley
   Examine the pump shaft for scoring, burrs, or damage. The shaft should be smooth and clean. Inspect the pulley bore for cracks, scoring, or deformation. Check the pulley faces and grooves for wear or cracking. Replace pulley if damaged. Clean the pump shaft with a wire brush and shop towel to remove any debris or rust.
7. 7

   Install new pulley onto pump shaft
   Position the new power steering pulley onto the pump shaft with the belt grooves facing outward. The pulley should slide onto the shaft approximately 1/8 to 1/4 inch by hand. Install the power steering pulley installation tool. This tool consists of a pressing screw that threads through a bridge or plate and bears against the pump shaft end, while the bridge pushes against the pulley face.
8. 8

   Press pulley onto shaft
   Thread the installation tool pressing screw through the bridge plate until it contacts the pump shaft end. Turn the screw clockwise while holding the tool bridge against the pulley face. Apply steady pressure to press the pulley onto the shaft. Continue pressing until the pulley hub is fully seated and flush with the end of the pump shaft, per the manufacturer's specification.
9. 9

   Remove installation tool and verify seating
   Remove the pulley installation tool from the pump shaft. Verify the pulley is fully seated and does not wobble or move on the shaft. Check that the pulley rotates freely without binding. Inspect alignment of the pulley with other belt-driven components.
10. 10

    Reconnect power steering lines if removed
    If disconnected in step 3, install new O-ring on pressure line fitting if applicable. Reconnect the power steering pressure line to the pump and tighten the fitting securely. Reconnect the return hose to the reservoir and secure with hose clamp. Reinstall any brackets removed for access.
11. 11

    Install and tension drive belt
    Route the drive belt over the power steering pump pulley, crankshaft pulley, and alternator pulley following the original routing pattern. Pull the alternator outward to create tension on the belt. The belt should deflect approximately 1/2 inch under firm thumb pressure at the longest span between pulleys. Tighten the alternator adjustment bolt, then tighten the pivot bolt to lock the alternator in position.
12. 12

    Refill power steering system
    Remove the power steering reservoir cap. Add Type F ATF to the reservoir until fluid reaches the fill/FULL mark on the dipstick or reservoir. Start the engine and turn the steering wheel slowly from lock to lock 3 times. Stop the engine and recheck fluid level. Add fluid as needed to reach the FULL COLD mark. Repeat until fluid level stabilizes and no air bubbles are visible in the reservoir.

Reassembly

1. Reconnect negative battery cable
2. Verify drive belt is properly routed and tensioned
3. Check for power steering fluid leaks at all connections
4. Wipe down all components and clean any spilled fluid from engine bay

Verification

• Start engine and verify no abnormal noises from power steering pump area
• Turn steering wheel from lock to lock while stationary and verify smooth operation without binding or noise
• Check power steering fluid level with engine at operating temperature and add if necessary to HOT mark
• Inspect pulley for wobble or misalignment while engine is running
• Test drive vehicle and verify normal power steering assist function
• Recheck fluid level after test drive and inspect for leaks

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