1996 3.0 v6 ford taurus..the power stearing pulley is only pulley on whole car that doest have a nut on it to replace the pulley.i got a kit from advance auto but my problem is that the bracket that holds the pump on which also holds the altinator is all attached to to block of then engine.i cant take the pump off and put the pulley on cause the pulley will not fit thru the hole of the bracket.i also need to know which way will the pulley be faceing,the lip of the pulley faceing away from the pump or towards the pump,the kit i got seens to force the pulley over the gear of the power stearing pump
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if you have not replaced the tension pulley and the idler pulley it might be them. but i too just had my power steering pump replaced and i took it back. the garage said that ford states that a manufactured pump has a 500 mile break in time. if after that then you have a bad pump and should be replaced again.
This may be helpful. Not familiar with '04, but 1998 Ford Taurus requires you to first pull off the power steering pump pulley using a pulley tool borrowed from a local parts store. The alternative is to break the pulley (plastic) with a hammer to get to the bolts and then use the pulley tool to
get the rest of the pulley loose and replace with another 10 or 11 dollar pulley after you have remounted the steering pump and bracket. The reason the pulley has to come off is there is another
bolt behind the pulley. Hope this is helpful.
There are a few different kinds. So take this into consideration. If it's the clamp type: loosen the side nuts and place the two arms into the groove on the front of the steering pump pulley and tighten them down as tight as you can. Take the bolt that goes into the center and tighten it just before it makes contact in the center of the pulley. If you have the spacer/washer to go on the end put it on and tighten the center nut to push in on the pump shaft INSIDE of the pulley. This should pull the pulley off while pressing on the inner shaft. (sometimes these things slip out of the pulley groove and you might have to use a "C" clamp to hold them together tight enough), while slipping a large wrench over the sides that dont have the jaws on them.
If it's the slip on type: back the bolt out of it. Slip it into the pulley groove and tighten the center bolt into the pulley, and make contact with the pump shaft, INSIDE of the pulley. Put a large wrench on the tool to hold it still, and tighten the center bolt.
What I'm afraid is that you're doing it inside of the engine compartment. And there's not much room. You may be able to get to it by removing the front tire and jacking the van up.
If you go to autozone.com, they have access to free repair manuals, you can print out step by step instructions from there. you will have to register with the sight and provide your vehicle information. it is free.
this is for the 3.0 v-6 OHV (2-valve).
you will need a couple of special tools,
disconnect the battery neg (black) terminal
remove the accessory drive belt
remove the alternator
remove and drain the coolant from the recovery reservoir
put a drain pan under Pwr STR pump under the vehicle and disconnect the lines and let them drain
remove the idler pulley
remove the bracket mounting bolt under the belt tension mounting
remove the 2 retaining nuts/ remove mounting studs/ remove Pwr Str Pump support w/ pump attached
clamp pump in vise/remove pulley (special tool)
remove three bolts on the support, remove Pwr Str pump.
replace as you have taken apart
when installing you will need the second tool "pump pulley replacer"
I just did it on a 99 sable w/ dual overhead cam.... You need to pull the pulley off first and expose three 10mm mounting bolts. I had a heck of a time getting the return line loose. I think it was a 18mm line wrench,
Take a ring spanner and put the ring side over the nut then use a hammer to tap the nut loose,if that does not work take a chisel and put it on the side of the nut and then tap with a hefty hammer until loose you will need to replace the nut afterwards thou