This procedure covers the removal and installation of the power steering pump pulley on the 2011-2014 Ford F-150 with 3.5L EcoBoost engine.

Warnings

Tools required

Parts

• Power steering pump pulley × 1 — Use OEM specification
• Power steering line O-rings × 2 — Use OEM specification
• Motorcraft MERCON LV × 1 — XT-10-QLVC

Fluids

• Motorcraft MERCON LV — 1 qt

Preparation

1. Park vehicle on level ground and engage parking brake
2. Allow engine to cool completely if recently operated
3. Disconnect negative battery cable
4. Remove engine cover if equipped
5. Place drain pan under power steering pump area

Procedure

1. 1

   Remove serpentine belt
   Rotate the belt tensioner clockwise using a breaker bar or serpentine belt tool. Remove the belt from the power steering pump pulley first, then release tensioner and remove belt completely. Note the belt routing diagram on the radiator shroud for reinstallation.
2. 2

   Disconnect power steering lines
   Using a line wrench, disconnect the pressure line fitting from the pump. Be prepared for fluid spillage. Disconnect the return line from the pump. Cap or plug all openings immediately to prevent contamination. Discard the old O-rings from both fittings.
   Torque spec

   Pressure Line Fitting39 Nm (29 lb-ft)
3. 3

   Remove pump mounting bolts
   Remove the three power steering pump mounting bolts. Support the pump while removing the final bolt. Carefully maneuver the pump out of the engine bay, avoiding damage to surrounding components.
   Torque spec

   Pump Mounting Bolts31 Nm (23 lb-ft)
4. 4

   Secure pump for pulley removal
   Place the pump on a clean workbench. Ensure the pump is stable and secure. Do not clamp the pump body in a vise as this can crack the housing. Use protective padding if additional support is needed.
5. 5

   Remove power steering pulley
   Install the power steering pulley puller tool onto the pulley. Thread the tool's center screw into the pump shaft threads. Tighten the puller evenly while holding the outer portion to pull the pulley straight off the shaft. Do not use impact tools or apply excessive side load to the shaft.
6. 6

   Inspect pump shaft and new pulley
   Inspect the pump shaft for damage, scoring, or wear. Check the shaft threads and keyway for integrity. Inspect the new pulley for proper fit and ensure the keyway aligns correctly. Clean the shaft with a lint-free cloth.
7. 7

   Install new pulley
   Align the pulley keyway with the shaft keyway. Use the pulley installer tool to press the pulley onto the shaft. Press the pulley on evenly until it is fully seated and flush with the end of the shaft. Do not hammer or impact the pulley onto the shaft as this will damage the pump bearings.
8. 8

   Reinstall power steering pump
   Position the pump back into the mounting bracket location. Install the three mounting bolts finger-tight, then torque to specification in a cross pattern to ensure even mounting pressure.
   Torque spec

   Pump Mounting Bolts31 Nm (23 lb-ft)
9. 9

   Reconnect power steering lines
   Install new O-rings on both the pressure and return line fittings. Lubricate O-rings lightly with clean power steering fluid. Connect the return line to the pump. Thread the pressure line fitting by hand first to prevent cross-threading, then torque to specification using a line wrench.
   Torque spec

   Pressure Line Fitting39 Nm (29 lb-ft)
10. 10

    Install serpentine belt
    Route the serpentine belt according to the routing diagram. Ensure the belt is properly seated in all pulley grooves. Rotate the tensioner clockwise and slip the belt over the final pulley. Release tensioner slowly to apply proper belt tension.
11. 11

    Fill and bleed power steering system
    Fill the power steering reservoir to the MAX cold fill line with Motorcraft MERCON LV. Start the engine and turn the steering wheel lock-to-lock slowly 10 times without holding at full lock. Check fluid level and top off as needed. Repeat until no air bubbles appear in the reservoir and fluid level stabilizes.

Reassembly

1. Reinstall engine cover if removed
2. Reconnect negative battery cable
3. Clean any spilled power steering fluid from engine bay and painted surfaces

Verification

• Check for power steering fluid leaks at pump fittings with engine running
• Verify pulley rotates smoothly without wobble or noise
• Test power steering operation by turning wheel lock-to-lock at idle - should be smooth with no whining or groaning
• Recheck fluid level after test drive and top off to cold fill line if needed
• Verify serpentine belt is properly seated and tensioned with no unusual noise

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