Power steering pump replacement

MATT CRAWFORD

MEMBER
2003 CHEVROLET SILVERADO
6.0L
V8
2WD
AUTOMATIC
99,300 MILES

The pulley removal tool was working well, slowly pulling the power steering pump pulley off like it should. It moved roughly 3/8 of an inch off the shaft before the collar assembly started turning crooked as torque was applied. So, I stopped and took it off and the tool started shearing off the flange of the pulley. Just my luck. Fortunately, I'm planning on replacing both it and the pump. However, from what answers I can find on google, it seems like the pulley must come off in order to be able to get the power steering pump out. But no definite answer on whether it's even possible to take it off with the pulley still on. Or there is an alternate method to get the pulley off. I'm 4,500 miles away from home stationed in Hawaii and don't have access to any pneumatic tools or any blowtorch/heating tools.

4 Replies

JACOBANDNICKOLAS

MECHANIC
109,885 POSTS

Hi,

It needs to be removed. Otherwise, the room isn't there to remove the pump. Also, the lower intermediate shaft needs to be removed from the steering gear.

Can you take a pic of what is actually breaking and upload it for me to see? As far as the old pump, if you are replacing everything, I wouldn't be too worried if it gets damaged. However, not being there, I don't even know if that is an option.

If you look below, I attached the directions for this procedure specific to this truck.

Let me know if this helps or if you have other questions.

Take care,

Joe

See pics below.

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Tuesday, March 22nd, 2022 AT 9:07 PM

MATT CRAWFORD

MEMBER
6 POSTS

Hi Joe,

Apologies for the late response. Nothing was technically "broke". The steering box had a pretty good leak at the output shaft, so I've been having to top off the power steering pump reservoir about once every week and a half. I suspect the previous owner let the pump run too long without enough fluid because ever since I've owned it, it's had this constant faint whine that fluctuates with the rpms of the motor. And frankly I was tired of hearing it, so I decided to replace it at the same time as I was replacing the steering box.

Things have developed significantly since I first submitted my question; so just to update you, the new power steering pump and pulley have been installed, the system has been properly filled and bled of air, and the ole girl is buttoned up and back on her own weight (new pitman and idler arms as well).

I ended up removing the entire bracket that the idler pulley, alternator, and power steering pump mount to as one unit. I tried several different pulley removal tools, but they were practically useless because the pulley remover kit I used while the pump was still installed literally started shearing off the flange that the clamshell halves are supposed to grab onto. So, any time tq was applied to the pressure screw, the two halves would slip off due to the pulley flange shearing. So that's when."Alternate". Methods were used.
*Sawzall has entered the chat*
I cut the damn thing right in two, right behind the pulley. With the pulley, and uh, part of the pump now cleanly separated from the rest of the pump, I finally had access to the bolts holding it to the bracket. I popped the old pump off, pressed on the pulley, tossed the whole assembly back in, and it was smooth sailing from there. I attempted to attach a photo to my initial question, but I guess it didn't upload so you'll find a picture of the sheared flange of the old pulley attached to this message. The picture was taken while the pulley and pump were still installed in the truck.

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Wednesday, March 23rd, 2022 AT 1:27 AM

JACOBANDNICKOLAS

MECHANIC
109,885 POSTS

Hi,

I had to laugh when the word "Sawzall" was mentioned. I would have either done the same thing or something similar. LOL Whatever it takes!

The way I looked at it was this. Since you are replacing both parts, it really wouldn't matter if the old parts were damaged.

Regardless, I'm glad to hear it's fixed, and thanks for the update.

Please feel free to come back anytime in the future if you have questions. You're always welcome here. (Especially because you employed the use of construction tools to fix a car.)

Take good care of yourself,

Joe

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Wednesday, March 23rd, 2022 AT 4:19 PM

MATT CRAWFORD

MEMBER
6 POSTS

Haha, thanks for the help, Joe. This site and the wealth of knowledge its people possess is truly a goldmine in the midst of Google and all of its vague answers that never quite match folks' unique scenarios. Thanks again and take care as well!

-Matt

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Wednesday, March 23rd, 2022 AT 5:11 PM