Removal of 1997 ford aerostar power steering pump.

CAUTION: While repairing the power steering system, care should be taken to prevent the entry of contaminants or premature failure of the power steering components may result.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02 .

1. Using a suitable suction device, siphon the power steering fluid from the power steering fluid reservoir.

1. Remove the RH inner fender splash shield. For additional information, refer to Section 501-02 .

1. Using the special tool, disengage the power steering pump belt from the power steering pump pulley and position it aside.
   • Install the removal tool between the belt and the pulley and turn the crankshaft bolt clockwise to disengage the belt.

1. Remove the 4 bolts and position the driveshaft aside.

1. Using a suitable jack, support the rear of the subframe.

1. Remove the 2 nuts, 4 bolts and the subframe support brackets.

1. Remove the 2 middle subframe nuts.

1. Lower the rear of the subframe.

1. Release the clamp and disconnect the power steering supply hose from the power steering pump.

1. Disconnect the power steering pressure (PSP) switch electrical connector.

1. Remove the power steering pressure line fitting banjo bolt and disconnect the line from the power steering pump.
   • Discard the 2 seals.

1. Remove the 3 power steering pump bolts and the power steering pump. This is a job best left to a qualified repair shop !

Power Steering Pump - 4.0L Special Tool(s) Installer Set, Teflon® Seal
211-D027 (D90P-3517-A) or equivalent Material Item Specification MERCON® V Automatic Transmission Fluid
XT-5-QM (or XT-5-QMC) (US); CXT-5-LM12 (Canada) MERCON® V
Item Part Number Description 1 388898 Teflon® seal 2 - Pressure line-to-pump fitting (part of 3A719) 3 W700839 Power steering pump bolts (3 required) 4 3A674 Power steering pump 5 W503924 Pressure line bracket-to-engine bolt 6 3691 Power steering pump supply hose 7 W503924 Power steering pump supply hose bracket bolt
Removal
NOTICE: While repairing the power steering system, care should be taken to prevent the entry of foreign material or failure of the power steering components may result.

1. Using a suitable suction device, remove the power steering fluid from the reservoir.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02.

1. Remove the power steering pump pulley. For additional information, refer to Power Steering Pump Pulley - 4.0Lin this section.

1. Remove the pressure line bracket-to-engine bolt.

1. Remove the power steering pump supply hose bracket bolt.

1. Release the power steering pump supply hose clamp and disconnect the hose.

1. Disconnect the pressure line-to-pump fitting.
   • Remove and discard the Teflon® seal.

1. Remove the 3 bolts and the power steering pump.

Installation

1. NOTE:A new Teflon® seal must be installed.Using the Teflon® Seal Installer Set, install a new Teflon® seal to the pressure line fitting.

1. Position the power steering pump and install the 3 bolts.
   • Tighten to 25 Nm (18 lb-ft).

1. Connect the pressure line-to-pump fitting.
   • Tighten to 75 Nm (55 lb-ft).

1. Connect the power steering pump supply hose.

1. Install the power steering pump supply hose bracket bolt.
   • Tighten to 11 Nm (97 lb-in).

1. Install the pressure line bracket-to-engine bolt.
   • Tighten to 11 Nm (97 lb-in).

1. Install the power steering pump pulley. For additional information, refer to Power Steering Pump Pulley - 4.0Lin this section.

1. Fill the power steering system. For additional information, refer to Section 211-00.

Not that easy to change. You may need a crow's foot wrench on the fitting where the PS hose connects to the rack and pinion-on the car frame member behind the transaxle. Raise the driver front of car on stands, remove wheel. PS hoses, the pressure line and the return line, both connect at about the same place on the rack and pinion unit. See if you can get a regular wrench on the hose in question, and loosen it. If you can, (use rags or a can to catch leaks), then take off the hose in question up top on the PS pump, or on the PS reservoir. The pressure hose comes from the pump. The return hose goes to the reservoir-or some just both go to the pump and reservoir, if it's a single unit.
Suction out the fluid from reservoir before removing hose, or you will have a big mess to clean up afterward. If loosened from top and bottom, there should be a hose holding bracket on the backside of engine or transmission.
Good luck.

Remove the serp belt. Use a power steering pump pulley remover to remove the pulley. Remove the three bolts that hold the pump to the bracket. Rmove the high pressure line and the return line.

I’m happy to assist further over the phone at https://www.6ya.com/expert/jeremy_d728a59f986299fa

Belt Installation, Aerostar 4.0L Engine





Item Part Number Description 1 8620 Drive Belt 2 N606068 Bolt 3 10300 Generator 4 10153 Generator Mounting Bracket 5 8509 Water Pump Pulley 6 6B209 Drive Belt Tensioner 7 N800199 Screw 8 8678 Belt Idler Pulley 9 N802096 Screw 10 19703 A/C Compressor 11 2882 A/C Compressor Mounting Bracket 12 3C718 Brace 13 N806020 Bolt 14 3A674 Power Steering Pump 15 3A733 Power Steering Pump Pulley 16 N800199 Screw 17 N606572 Bolt 18 N620481 Nut 19 8501 Water Pump 20 6312 Crankshaft Pulley A - Belt Tension Check (See Specifications) B - Tighten to 40-55 Nm
(30-41 Lb-Ft) C - Tighten to 24-30 Nm
(18-23 Lb-Ft) D - Tighten to 21-29 Nm
(15-21 Lb-Ft) E - Tighten to 40-50 Nm
(30-37 Lb-Ft)

Belt Installation, Ranger and Explorer 4.0L Engine





Item Part Number Description 1 8620 Drive Belt 2 10300 Generator 3 8678 Belt Idler Pulley 4 19703 A/C Compressor 5 3A733 Power Steering Pump Pulley 6 8501 Water Pump 7 6312 Crankshaft Pulley 8 6B209 Drive Belt Tensioner 9 N806020 Bolt 10 2882 A/C Compressor Mounting Bracket 11 3A674 Power Steering Pump 12 N606572-S2 Bolt 13 N800199-S8M Bolt 14 N620481-S2 Nut 15 3C718 Brace 16 N606068 Bolt 17 10153 Generator Mounting Bracket 18 8509 Water Pump Pulley 19 N605805-S2 Bolt A - Belt Tension Check (See Specifications) B - Tighten to 21-29 Nm
(15-21 Lb-Ft) C - Tighten to 40-55 Nm
(30-41 Lb-Ft)

Belt Installation, Ranger 2.3L Engine





Item Part Number Description 1 8678 Belt Idler Pulley 2 10300 Generator 3 8509 Water Pump Pulley 4 3A733 Power Steering Pump Pulley 5 2E884 A/C Clutch Pulley 6 6312 Crankshaft Pulley

Belt Installation, Aerostar 3.0L Engine





Item Part Number Description 1 10300 Generator 2 3F671 Belt Idler Pulley 3 3A733 Power Steering Pump Pulley 4 6B209 Drive Belt Tensioner 5 6312 Crankshaft Pulley 6 8509 Water Pump Pulley 7 19703 A/C Compressor

Section 11-02A: Steering Pump, Power, C-II 1996 Aerostar, Ranger and Explorer Vehicles Workshop Manual REMOVAL AND INSTALLATION Pump and Pulley SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Steering Pump Pulley Remover T69L-10300-B Steering Pump Pulley Replacer T65P-3A733-C
Removal

1. Disconnect the power steering return hose (3A713) at the pump and drain fluid.
   

1. Remove the power steering pressure hose (3A719) by unscrewing connector from the pump.
   

1. On the Aerostar 3.0L V-6 engine (6007), loosen the drive belt tensioner (6B209) and adjustment bolts.
   
   
   
   
   
   Item Part Number Description 1 10346 Generator 2 8501 Water Pump 3 8678 Belt Idler Pulley 4 3A733 Power Steering Pump Pulley 5 6303 Crankshaft 6 2884 A/C Clutch 7 — Without A/C On the 2.3L I-4 and 4.0L V-6 engines, slacken belt tension by lifting drive belt tensioner in a counterclockwise direction. On Ranger 3.0L V-6 engines, slacken belt tension by lifting drive belt tensioner in a clockwise direction. Remove drive belt (8620) from under drive belt tensioner and slowly lower pulley to stop. Remove the drive belt from the power steering pump pulley (3A733).
   
   
   
   
   
   Item Part Number Description 1 10346 Generator 2 2884 A/C Clutch 3 3A733 Power Steering Pump Pulley 4 8501 Water Pump 5 6303 Crankshaft 6 8678 Belt Idler Pulley 7 6B209 Drive Belt Tensioner

1. NOTE: If the drive belt requires servicing, refer to Section 03-05 .
   
   Remove the drive belt from the power steering pump pulley.
   

1. Remove the oil dipstick tube.
   

1. Remove the power steering pump support (3C511).
   

1. Install Steering Pump Pulley Remover T69L-10300-B on the pulley.
   

1. NOTE: Do not apply pressure on the power steering pump rotor shaft (3B559). Pressure will damage internal thrust areas of the power steering pump (3A674).
   
   While holding the remover tool nut stationary with a wrench, rotate the inner spindle of the remover tool clockwise until the pulley is pulled off the power steering pump rotor shaft.
   

1. Remove the bolts attaching the power steering pump to the A/C compressor mounting bracket (2882).
   

Installation

1. Install the power steering pump on the A/C compressor mounting bracket. Install and tighten attaching bolts to 41-61 Nm (30-45 lb-ft). On 4.0L engine, tighten to 47-64 Nm (35-47 lb-ft).
   

1. Position the support on the A/C compressor mounting bracket. Install mounting bolts and tighten to 47-64 Nm (35-47 lb-ft).
   

1. NOTE: Fore/aft location of power steering pump pulley on power steering pump rotor shaft is critical. Incorrect belt alignment may cause drive belt squeal or chirp. Make sure pull-off groove on power steering pump pulley is facing front and flush with end of shaft ± 0.254mm (± 0.010 inch).
   
   Install the Steering Pump Pulley Replacer T65P-3A733-C and install the power steering pump pulley.
   

1. Install the drive belt on the power steering pump pulley.
   

1. On the 2.3L I-4, Ranger 3.0L V-6, and 4.0L V-6 engines, position and rotate drive belt on engine. While lifting drive belt tensioner in a counterclockwise direction (clockwise on Ranger 3.0L V-6), slide drive belt under drive belt tensioner and lower drive belt tensioner to drive belt.
   On Aerostar 3.0L V-6 engine, position the belt idler pulley (8678) assembly to give the drive belt the tension specified. Refer to belt tension check in Section 03-05 . Tighten the drive belt tensioner and adjustment bolts to 47-64 Nm (35-47 lb-ft).
   

1. Install the power steering pump support, if removed.
   

1. Install the oil dipstick tube.
   

1. Install the pressure hose tube nut and new Teflon® wagner into power steering pump valve outlet fitting (3D654) and tighten to 41-54 Nm (30-40 lb-ft).
   

1. Connect the power steering return hose to the power steering pump, and reposition the clamp.
   

1. Fill the power steering oil reservoir (3A697) with Premium Power Steering Fluid E6AZ-19582-AA or equivalent fluid meeting specification ESW-M2C33-F. Start the engine and turn the steering wheel (3600) from left to right without hitting stops to remove air from the system.
   

1. Check for leaks and recheck the fluid level. Add fluid if necessary to proper level as specified in Section 11-00 .
   
   
   Power Steering Pump and Power Steering Pulley, 2.3L TPH Engine, Ranger Only
   
   
   
   
   
   Item Part Number Description 1 2882 A/C Compressor Mounting Bracket 2 N606543-S2 Bolt (2 Req'd) 3 N606069-S2 Bolt (2 Req'd) 4 N605803-S2 Bolt 5 N800199-S8M Screw 6 3D673 Power Steering Pump Pulley 7 3F671 Power Steering Belt Idler Support 8 N806020-S2 Bolt 9 3A674 Power Steering Pump 10 19703 A/C Compressor A — Tighten to 21.2-29 Nm (16-21 Lb-Ft) B — Tighten to 40.3-55 Nm (30-41 Lb-Ft) C — Tighten to 44-51 Nm
   (32-38 Lb-Ft)
   
   Power Steering Pump and Power Steering Pulley, 3.0L Engine, Aerostar
   
   
   
   
   
   Item Part Number Description 1 3A674 Power Steering Pump 2 3C511 Power Steering Pump Support 3 6007 Engine 4 N803564 Stud 5 N802827-S2 Nut 6 N800199-S8M Screw (3 Req'd) 7 N8011179-S2 Screw (3 Req'd) 8

Chrysler Cirrus/Stratus/Sebring/Avenger/Breeze 1995-1998
Power Steering Pump - REMOVAL & INSTALLATION

Cirrus, Stratus, Sebring Convertible and Breeze
(see Figures 1, 2, 3 and 4)

1. Disconnect the negative battery cable from the left strut tower. The ground cable is equipped with an insulator grommet, which should be placed on the stud to prevent the negative battery cable from accidentally grounding.
2. Siphon as much power steering fluid out of the reservoir as possible.
3. Raise and safely support the vehicle.
4. Remove the right front tire and wheel assembly.
5. Remove the splash shield from the right front wheel well.

Fig. 1: Power steering pressure hose attachment to the pump-with Variable-Assist steering



Fig. 2: Power steering pressure hose attachment to the pump-without Variable-Assist steering

1. Disconnect the power steering pressure hose from the pump.
2. Remove the hose connection on the power steering pump.
   

Fig. 3: Typical power steering pump front bracket attachment

1. Remove the power steering adjusting bolt.
2. Remove the power steering pump rear attaching bolt.
3. If so equipped, remove the Anti-lock Brake System (ABS) hydraulic control unit heat shield.
4. Remove the wheel speed sensor retainer bracket from the right inner fender.
5. Remove the wheel speed sensor sealing grommet from the right inner fender.
6. Disconnect the speed sensor wiring.
7. Push the wiring through the hole in the inner fender.
   

If not equipped with anti-lock brakes, the hole will just have a sealing plug.

1. Remove the bolt attaching the power steering front bracket to the mounting bracket. Access to the bolt is gained through the hole for the speed sensor wiring.
2. Remove the power steering pump drive belt.
3. Remove the power steering pump and the front bracket as an assembly.
   

To install:

1. Install the power steering pump and bracket.
2. Reinstall the bolt at the adjusting slot, but do not tighten.
3. Reinstall the bolt mounting the power steering pump to the rear mounting bracket, but do not tighten.
4. Reinstall the power steering pump top bolt, but do not tighten.
5. Reconnect the power steering hoses.

Fig. 4: Install a new O-ring gasket on the hose fitting
Use a new O-ring when reinstalling the power steering pressure hose.

1. Reinstall the drive belt.
2. Adjust the drive belt and tighten the power steering pump bolts to 40 ft. lbs. (54 Nm).
3. Reinstall the splash shield.
4. Reinstall the tire and wheel assembly.
5. Lower the vehicle.
6. Reconnect the negative battery cable.
7. Refill the reservoir and bleed the power steering system.

Sebring Coupe and Avenger

1. Disconnect the negative battery cable.
2. Remove (drain, suction pump, etc.) as much power steering fluid as possible.
3. Disconnect the return fluid line. Remove the reservoir cap and allow the return line to drain the fluid from the reservoir. If the fluid is contaminated, disconnect the ignition high tension cable and crank the engine several times to drain the fluid from the gearbox.

Cover any components located underneath the power steering pump with a shop towel to protect them from damage due to power steering fluid spillage. For example, the A/C compressor or alternator, depending on vehicle and engine, is below the power steering pump, so cover the A/C compressor or alternator with a shop towel before removing any hoses.

1. Loosen (but do not remove) the power steering pump mounting bolts and remove the drive belt.
2. Remove the pressure switch connector from the side of the pump.
3. Disconnect the pressure line.
4. Unbolt and remove the pump from the mounting bracket.

To install:

1. Clean all parts well. Inspect the pump pulley for cracks. Check the hoses carefully for cracks or signs of weakness.
2. Install the pump, wrap the belt around the pulley and lightly tighten the mounting bolts.
3. Replace the O-rings and connect the pressure line. Connect the pressure line so the notch in the fitting aligns and contacts the pump's guide bracket. Tighten the fitting to 13 ft. lbs. (18 Nm).
4. Connect the return line and secure with the clamp.
5. Fasten the pressure switch connector.
6. Adjust the power steering belt for proper tension and tighten the adjusting bolts.

Use only MOPAR ATF PLUS automatic transmission fluid type 7176, ATF+3 automatic transmission fluid, or equivalent, in the power steering system of Sebring coupe and Avenger models.

1. Refill the reservoir and bleed the power steering system.

Hope this help to solve it (remember comment and rated this). TY for using Fixya.

Pretty easy for average mech. first drain coolant by loosening the lower radiator hose.
Make sure to have a drain pan. remove the power steering belt by removing the bolts to the idler pulley. and let belt off the pulley.remove the alternator upper bracket. and remove belt.
Take fan shroud off with two 8mm bolts on top oe it.
You cant remove untill you remove the clutch fan assembly.
It is left handed thread.
It has to be removed together.
Remove the four bolts to the pulley on front of water pump. and then remove all 14mm bolts around the pump.
Then remove 8mm bolts and it will be able to come off. assemble in reverse order!

Creating More Workspace:
It is necessary to remove the CAC to inlet manifold pipe (drivers side) i.e. the wide, black pipe bolted to the top of the engine, to gain access to the P.S. pump and move the Engine Coolant Resevoir to one side.
Also, to make the process easier and create additional space, it may be helpful to remove the following additional items from the car:

• fuel filter (and plastic retaining clip).
• oil filter (to make access easier to the nuts bolts and pipes from below the car)
• the EGR cooler connection pipe (optional).

Essential Items:

• 15mm Deep, Hex Socket and large 15mm Ring Spanner - tensioner mounting nuts
• E8 Torx Spanner for removing 3 studs with T40 Torx ends (method 2 only)
• 18mm (or 3/8W, 7/16BS) Crowfoot wrench for removing union nut on HP pipe power steering pump. (method 1 only)
• 10mm ring or combination spanners, long and short (P.S. Pump).
• 10mm, hex socket ( narrower 3/8" drive preferred) - power steering pump bolts (Methods 1 and 2)
• Hose Clamp (clamping bottom hose power steering pump)
• Teflon seal / o-ring for union on HP Line, Power Steering Pump or new union (See Notes 2 & 3)

Power steering pump special tools


Power Steering Pump Removal & Installation Power Steering Pump (2V) To Remove:

1. Before servicing the vehicle refer to the precautions at the beginning of this section.
2. Disconnect the battery ground cable.
3. Remove the accessory drive belt.
4. Remove the alternator.
5. Drain and remove the radiator coolant recovery reservoir.
6. Position a drain pan under the power steering pump underneath the vehicle. Disconnect the hydraulic pressure and return lines and allow to drain.
7. Remove the idler pulley from the power steering pump support.
8. Remove the belt tensioner.
9. Remove the bracket mounting bolt located under the belt tensioner mounting.
10. Remove two retaining nuts from the bracket mounting studs. Remove both mounting studs, and pull off the power steering pump support with the pump attached.
11. Clamp the pump support bracket in a suitable vise.
12. Remove the power steering pump pulley from the pump shaft using Pump Pulley Remover T69L-10300-B, or equivalent. Remove the three bolts retaining the power steering pump to the power steering pump support and remove the power steering pump.

To Install:
NOTE: The pulley must be installed within 0.010 in (0.25 mm) flush with the power steering pump shaft.

1. Install the power steering pump to the power steering pump support. Tighten the mounting bolts to 18 ft-lb. (25 Nm).
2. Install the power steering pump pulley using Steering Pump Pulley Replacer T65P-3A733-C, or equivalent; the pulley face must be flush within 0.010 inch (0.25mm) of the pump shaft.
3. Install the power steering pump/pump support and torque nuts/bolt to 24 ft. lbs. (33 Nm).
4. Install the bracket mounting bolt located under the belt tensioner mounting.
5. Install the belt tensioner.
6. Install the idler pulley to the power steering pump support.
7. Connect the hydraulic pressure and return lines.
8. Install the radiator coolant recovery reservoir.
9. Install the alternator.
10. Install the accessory drive belt.
11. Fill the power steering reservoir with power steering fluid.
12. Connect the battery ground cable.
13. Run the engine and check for leaks and proper operation. Bleed the power steering system if needed.