Power Steering Pump Pulley on a 1994 Chevy 2500

This is the procedure in the AUTO ZONE repair help...note that it has you remove the hoses AFTER removal of the pump. If they could be removed in place it would have had you do that prior to pump removal.

3.5L & 3.9L Engines

Please note that the power steering pump pulley must be removed to access the pump retaining bolts. Special tools are required to draw the pulley off the pump shaft and to later press the pulley onto the pump shaft. A shop press cannot be used to install the pulley or the pump will be damaged.

1. Place a drain pan under the vehicle.
2. Remove the coolant surge tank (coolant reservoir).
3. Remove the cosmetic/acoustic engine cover.
4. Remove the accessory drive belt.
5. Remove the accessory wiring junction block and set aside.
6. Remove the power steering pump pulley from the pump noting the following:
   1. Use a power steering pump pulley remover. These pullers typically have a ridge that surrounds the collar on the pulley center.
   2. Turn the puller screw making sure the center screw is centered in the end of the pump shaft.
   3. Draw the pulley from the pump shaft.
7. Disconnect the pressure line and return hose from the power steering pump.
8. Unfasten the pump retaining bolts and remove the pump from the engine.

Fig. Power steering pump mounting and the pulley removal and installation tool.

To install:

1. Install the pump to the engine. Install the bolts and tighten to 25 ft. lbs. (34 Nm).
2. Connect the power steering return line.
3. Connect the power steering pressure line. Using a -crows foot- adapter and a torque wrench, torque the pressure line fitting to 20 ft. lbs. (27 Nm).
4. Install the power steering pump pulley noting the following.
   1. Use a power steering pump pulley installer such as J 36015, or equivalent. This type of installer threads into the end of the pump shaft. A nut is then turned to press the pulley onto the pump shaft.
   2. The face of the pulley hub must be flush with the end of the pump shaft.
      
      WARNING
      Do not attempt to use a shop press to install a pump pulley.

Hi Brian:
Check this REMOVAL and INSTALLATION procedure... (see Figures 2, 3 and 4)

1. Position a fluid catch pan under the power steering pump.
   
2. Disconnect the feed and return hoses from the power steering pump, then drain the excess fluid into the catch pan.
   

On models equipped with a remote fluid reservoir, disconnect and plug the hose(s) in order to prevent system contamination or excessive fluid loss.

1. Remove the drive belt from the pulley.
   
2. Install a puller tool such as J-25034, or equivalent onto the power steering pump pulley. While holding the pilot bolt, turn the tool nut counterclockwise in order to press the drive pulley from the pump.

When installing the puller tool onto the power steering pump pulley, be sure that the pilot bolt bottoms in the pump shaft by turning the head of the pilot bolt.

Fig. 2: Installing the pilot bolt



Fig. 3: Removing the power steering pump pulley

Fig. 4: Installing the power steering pump pulley

1. On most models, it may be necessary to unplug the electrical connection from the A/C compressor, unfasten the compressor mounting bolts and set the compressor to one side without disconnecting the lines.
   
2. If equipped, unfasten the power steering filler tube bolt and remove the filler tube.
   
3. Remove the rear brace retainers and the brace.
   
4. Remove the power steering pump-to-bracket bolts and then remove the pump from the vehicle.
   

To install:

1. Position the pump to the vehicle and secure using the front retaining bolts to 22 ft. lbs. (30 Nm) 2.2L engines. (50 Nm). On 4.3L engines tighten the bolts to 37 ft. lbs. (50 Nm).
   
2. If equipped, install the rear brace and tighten the retainers to 22 ft. lbs. (30 Nm) on 1994-98 2.2L engines. On 1999 2.2L engines, tighten the brace retainers to 37 ft. lbs. On 1994 4.3L models tighten the retainers to 24 ft. lbs. (33 Nm). On 1995-99 4.3L models, tighten the retainers to 31 ft. lbs. (41 Nm).
   
3. If removed, install the A/C compressor.
   
4. If removed, install the filler tube and its retainer. Tighten the retainer to 15 ft. lbs. (20 Nm).
   
5. Use a pulley installer such as J-25033 or equivalent to press the drive pulley onto the power steering pump. While holding the pilot bolt, turn the tool nut clockwise in order to press the drive pulley onto the pump. Check that the pulley is flush within 0.010 in. (0.25mm) of the shaft end.

When positioning the installer tool onto the power steering pump pulley, be sure that the pilot bolt bottoms in the pump shaft by turning the head of the pilot bolt.

1. Properly install the drive belt and, if applicable, adjust the tension.

Be sure to secure any hoses which may get in the way or rub other components.

1. Remove the caps, then connect the feed and return hoses to the pump.
   
2. Properly refill and bleed the power steering system.
   
3. Test drive the vehicle.

Hope this helps; also keep in mind that your feedback is important and I`ll appreciate your time and consideration if you leave some testimonial comment about this answer.

Thank you for using FixYa, have a nice day.

To remove the pulley wheel from the power steering pump you typically have to remove 3 bolts but to get to those 3 bolts you have to use a socket and go through the holes on the pulley itself.

Power Steering Pump Removal & Installation 2.2L Engine To Remove:

1. Remove the upper cooling fan shroud.
2. Position a fluid catch pan under the power steering pump.
3. Disconnect the feed and return hoses from the power steering pump, then drain the excess fluid into the catch pan. NOTE: On models equipped with a remote fluid reservoir, disconnect and plug the hose(s) in order to prevent system contamination or excessive fluid loss.
   
4. Remove the drive belt from the pulley.
5. Install a puller tool such as J-25034, or equivalent onto the power steering pump pulley. While holding the pilot bolt, turn the tool nut counterclockwise in order to press the drive pulley from the pump. NOTE: When installing the puller tool onto the power steering pump pulley, be sure that the pilot bolt bottoms in the pump shaft by turning the head of the pilot bolt.
   Installing the pilot bolt
   
   Removing the power steering pump pulley
   
   Installing the power steering pump pulley
   
   
6. Unplug the electrical connection from the A/C compressor, unfasten the compressor mounting bolts and set the compressor to one side without disconnecting the lines.
7. Remove the front mounting bolts and the rear bracket nuts from the studs on the engine.
8. Remove the rear brace mounting bolt.
9. Remove the power steering pump from the vehicle.

To Install:

1. Position the pump to the vehicle and secure using the front retaining bolts to 22 ft. lbs. (30 Nm).
2. Install the rear bracket bolt and nuts. Tighten the retainers to 22 ft. lbs. (30 Nm) on 1994 - 97 models and 37 ft. lbs. (50 Nm) on 1998 and later models.
3. Install the A/C compressor.
4. Use a pulley installer such as J-25033 or equivalent to press the drive pulley onto the power steering pump. While holding the pilot bolt, turn the tool nut clockwise in order to press the drive pulley onto the pump. Check that the pulley is flush within 0.010 in. (0.25mm) of the shaft end. NOTE: When positioning the installer tool onto the power steering pump pulley, be sure that the pilot bolt bottoms in the pump shaft by turning the head of the pilot bolt.
   
5. Properly install the drive belt.
6. Remove the caps, then connect the feed and return hoses to the pump.
7. Properly refill and bleed the power steering system.
8. Test drive the vehicle.

4.3L Engine To Remove:

1. Remove the upper cooling fan shroud.
2. Remove the drive belt.
3. Remove the fan and clutch from the water pump.
4. Install a puller tool such as J-25034, or equivalent onto the power steering pump pulley. While holding the pilot bolt, turn the tool nut counterclockwise in order to press the drive pulley from the pump.
5. Safely raise and support the vehicle.
6. Remove the shield from the steering linkage.
7. Position a fluid catch pan under the power steering pump.
8. Disconnect the return hose from the power steering pump, then drain the excess fluid into the catch pan.
9. Safely lower the vehicle.
10. Disconnect the pressure hose from the pump and cap the open line.
11. Remove the filler neck tube.
12. Remove the power steering pump mounting nuts and bolts.
13. Remove the power steering pump from the vehicle.

NOTE: When installing the puller tool onto the power steering pump pulley, be sure that the pilot bolt bottoms in the pump shaft by turning the head of the pilot bolt.
Installing the pilot bolt

Removing the power steering pump pulley

Installing the power steering pump pulley

To Install:

1. Position the pump to the vehicle.
   • Tighten the front retaining bolts to 37 ft. lbs. (50 Nm) and the nuts to 31 ft. lbs. (41 Nm).
2. Install the filler neck tube.
   • Tighten the bolt to 15 ft. lbs. (20 Nm).
3. Connect the pressure hose to the pump.
4. Safely raise and support the vehicle.
5. Connect the return hose to the vehicle.
6. Install the shield on the steering linkage and lower the vehicle.
7. Use a pulley installer such as J-25033 or equivalent to press the drive pulley onto the power steering pump. While holding the pilot bolt, turn the tool nut clockwise in order to press the drive pulley onto the pump. Check that the pulley is flush within 0.010 in. (0.25mm) of the shaft end. NOTE: When positioning the installer tool onto the power steering pump pulley, be sure that the pilot bolt bottoms in the pump shaft by turning the head of the pilot bolt.
   
8. Install the fan and clutch on the water pump.
9. Properly install the drive belt. NOTE: Be sure to secure any hoses which may get in the way or rub other components.
   
10. Install the upper fan shroud.
11. Properly refill and bleed the power steering system.
12. Test drive the vehicle.

you need a belt rope wrench to hod the pulley, however you can remove it without taking the pulley off and put it in a vice to get it off. you will need a 3/8 ths drive ratchet to get it out with and tap it with a hammer also use a torch to heat up the outer edge to get the lock tight break loose.

if there is a dimple in the middle of the shaft, then you will probably need a pulley remover. make sure you havent missed any bolts that you have to go through little holes on the pulley to get to also. and also turn the pulley and look for any bolts that hold it on that are on the sides of the pulley, like a allen key bolt but on the side of the pulley that holds it on that way. i hope this helps

1. Disconnect battery ground cable, then remove exhaust manifold heat shield.
2. Disengage power steering pump reservoir hose from pump bracket and engine lifting bracket, then disconnect return hose and reservoir pump hose from pump.
3. Allow fluid to drain into a suitable container, then raise and support vehicle.
   1. Remove lower belt guard, then rotate drive belt tensioner clockwise as viewed from direction shown, and remove accessory drive belt.
   2. Lower vehicle, then remove traction assist module bolts and position module aside.
   3. Rotate power steering pump pulley to gain access to each pump front mounting bolt, then remove three front bolts and one rear bolt and lift pump from vehicle.
   4. If it is necessary to separate pulley from power steering pump, proceed as follows:
   1. install power steering pump pulley remover T69L-10300-B, or equivalent, on pulley hub.
   2. Clamp hex head of tool in a suitable vise, then hold power steering pump in place while turning tool nut counterclockwise. Do not apply inward or outward force on power steering pump shaft, internal pump damage may result.
   3. Slide pulley from power steering pump shaft.
   1. Reverse procedure to install, noting following:
   1. If pulley and power steering pump were separated, install pulley on pump shaft using power steering pump pulley replacer T91P-3A733-A, or equivalent. Ensure threads on end of tool are fully engaged in power steering pump shaft; after pulley installation, ensure end of shaft is within 0.010 inch of being flush with pulley surface.
   2. When placing pump in vehicle, install rear mounting bolt first, but do not tighten until three front bolts are in position.
      1. Rotate drive belt tensioner clockwise as viewed from direction shown to install accessory drive belt.
      2. Refill power steering fluid reservoir and bleed system.

REMOVAL & INSTALLATION

See Figures 2, 3 and 4

1. Position a fluid catch pan under the power steering pump.
2. Disconnect the feed and return hoses from the power steering pump, then drain the excess fluid into the catch pan.

On models equipped with a remote fluid reservoir, disconnect and plug the hose(s) in order to prevent system contamination or excessive fluid loss.

1. Remove the drive belt from the pulley.
2. Install a puller tool such as J-25034, or equivalent onto the power steering pump pulley. While holding the pilot bolt, turn the tool nut counterclockwise in order to press the drive pulley from the pump.

When installing the puller tool onto the power steering pump pulley, be sure that the pilot bolt bottoms in the pump shaft by turning the head of the pilot bolt.


Fig. Fig. 2: Installing the pilot bolt


Fig. Fig. 3: Removing the power steering pump pulley


Fig. Fig. 4: Installing the power steering pump pulley

1. On most models, it may be necessary to unplug the electrical connection from the A/C compressor, unfasten the compressor mounting bolts and set the compressor to one side without disconnecting the lines.
2. If equipped, unfasten the power steering filler tube bolt and remove the filler tube.
3. Remove the rear brace retainers and the brace.
4. Remove the power steering pump-to-bracket bolts and then remove the pump from the vehicle.

To install:

1. Position the pump to the vehicle and secure using the front retaining bolts to 22 ft. lbs. (30 Nm) 2.2L engines. (50 Nm). On 4.3L engines tighten the bolts to 37 ft. lbs. (50 Nm).
2. If equipped, install the rear brace and tighten the retainers to 22 ft. lbs. (30 Nm) on 1994-98 2.2L engines. On 1999 2.2L engines, tighten the brace retainers to 37 ft. lbs. On 1994 4.3L models tighten the retainers to 24 ft. lbs. (33 Nm). On 1995-99 4.3L models, tighten the retainers to 31 ft. lbs. (41 Nm).
3. If removed, install the A/C compressor.
4. If removed, install the filler tube and its retainer. Tighten the retainer to 15 ft. lbs. (20 Nm).
5. Use a pulley installer such as J-25033 or equivalent to press the drive pulley onto the power steering pump. While holding the pilot bolt, turn the tool nut clockwise in order to press the drive pulley onto the pump. Check that the pulley is flush within 0.010 in. (0.25mm) of the shaft end.

I don't have chrysler producs. I'll post 3.8L V6 Ford Windstar for reference. You'll get some idea.



Removal
WARNING: USE CAUTION WHEN REMOVING OR INSTALLING DRIVE BELT TO MAKE SURE THAT TOOL DOES NOT SLIP.

1. Using a 15mm socket or wrench on bolt attaching drive belt tensioner pulley. Rotate drive belt tensioner (6B209) clockwise to remove drive belt from pulleys.
   
   3.8L Engine
   
   

Item Part Number Description 1 10300 Generator 2 3A674 Power Steering Pump 3 19703 A/C Compressor 4 6B217 Drive Belt Tensioner Pulley 5 6312 Crankshaft Pulley 6 8501 Water Pump 7 6B209 Drive Belt Tensioner 8 8620 Drive Belt
Installation

1. Install drive belt over all pulleys (except drive belt tensioner ).

1. Rotate drive belt tensioner as described under Removal and install drive belt over drive belt tensioner pulley. Ensure that all V-grooves make proper contact with pulleys

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Another example
Pulley, Power Steering Pump CII
SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Steering Pump Pulley Remover T69L-10300-B Steering Pump Pulley Replacer T65P-3A733-C
Removal

1. Drain as much fluid as possible from the power steering pump (3A674) through the power steering oil reservoir (3A697) neck.

1. Install Steering Pump Pulley Remover T69L-10300-B on the power steering pump pulley (3A733) , and place the tool and power steering pump in a vise by gripping the small hex-head of the tool.

1. Hold the power steering pump , and rotate the tool nut counterclockwise to remove the power steering pump pulley . Do not apply in and out pressure on the power steering pump shaft. Pressure will damage the internal thrust areas.
   
   

Installation
CAUTION: Do not apply in and out pressure on the shaft. Pressure will damage the internal thrust areas.

1. Place the power steering pump pulley on the power steering pump shaft, and install Steering Pump Pulley Replacer T65P-3A733-C. The small diameter threads on the tool should be fully engaged in the power steering pump shaft.

1. Hold the power steering pump , and rotate the tool nut clockwise to install the power steering pump pulley on the shaft. The power steering pump pulley face must be flush within 0.25mm (0.010 inch) of the end of the power steering pump shaft.

1. Remove the tool.

1. Fill the power steering oil reservoir to the COLD FILL line.

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Steering Pump, Power Removal

1. Disconnect battery ground cable (14301) .

1. Remove accessory drive belt (8620) .

1. Raise vehicle on hoist. Refer to Section 00-02 .

1. Remove right front wheel (1007) and tire assembly.

1. Remove power steering pump pulley (3A733) .

1. Position drain pan. Remove power steering pressure hose (3A719) and power steering return hose (3A713) from power steering pump (3A674) .

1. Remove four power steering pump retaining bolts (three in front, one in rear) and remove power steering pump .

Installation

1. Position power steering pump and install retaining bolts. Tighten retaining bolts to 41-54 Nm (30-40 lb-ft).

1. Install power steering pressure hose and power steering return hose to power steering pump . Remove drain pan.

1. Press on power steering pump pulley as outlined in this section.

1. Install right front wheel and tire assembly. Tighten lug nuts (1012) to 115-142 Nm (85-105 lb-ft).

1. Lower vehicle.

1. Install drive belt to power steering pump pulley .

1. Connect battery ground cable .

1. Fill power steering oil reservoir (3A697) to proper level. Refer to Section 11-00 .
   
   Power Steering Pump and Bracket, 3.8L
   
   

Item Part Number Description 1 N607528-S2 Screw, M6-1 x 16 2 8509 Water Pump Pulley 3 W804804-S2 Screw, M8-1.25 x 35 4 N806214-S2 Bolt, M12 5 W606691-S36B Screw, M8-1.25 x 35 6 10B315 Generator Brace 7 N621939-S36B Nut, M8-1.0 8 10300 Generator 9 6B212 Accessory Drive Belt Tensioner Bracket 10 6049 Cylinder Head 11 19D624 Air Conditioning Compressor Bracket 12 W606563-S2 Bolt, M10-1.5 x 55 13 19703 A/C Compressor 14 N807273-S100 Bolt, M8-1.25 x 121.5 15 3C510 Power Steering Hose Bracket 16 3A674 Power Steering Pump 17 3C511 Power Steering Pump Support 18 W807239-S8 Bolt, M10-1.5 x 36.5 19 2888 A/C Compressor Brace 20 W806342-S2 Bolt, M8-1.25 x 23 21 W606571-S411 Bolt, M10-1.5 x 113.5 22 6C348 Idler Assembly 23 3A733 Power Steering Pump Pulley 24 N805137-S56 Bolt, M10-1.5 x 157 25 N621939-S2 Nut, M8-10 26 N807241-S36B Bolt, M10-1.5 x 132 27 6B209 Drive Belt Tensioner A — Tighten to 8-11 Nm (71-101 Lb-In) B — Tighten to 20-25 Nm (15-18 Lb-Ft) C — Tighten to 70-95 Nm (52-70 Lb-Ft) D — Tighten to 40-55 Nm (30-40 Lb-Ft) E — Press Flush with End of Power Steering Pump Shaft

Yep, Their Right. A Salvage Yard is your Only Choice. although you can try Chevy-Classic-Parts.com They are here in OKC and carry a LOT of Classic Parts.