Disassembly and Assembly

Disassembly

1. Remove power steering pump.
2. Mount pump in a suitable vise.
3. Using special service tool No. 09278-54012 or equivalent, remove pulley set nut. Remove pulley.

Fig. 9 Exploded View Of Power Steering Pump:

4. Remove suction port union and O-ring, Fig. 9.
5. Remove pressure port union and O-ring.
6. Remove flow control valve and spring.
7. Using suitable snap ring pliers, remove spring seat snap ring.
8. Temporarily install a bolt into the spring seat then remove the spring seat.
9. remove vane pump shaft with bearing as follows:
a. Using suitable snap ring pliers, remove pump shaft snap ring.
b. Temporarily install appropriate plate washer and pulley nut on shaft, then remove shaft using puller set tool No. 09910-00015 or equivalent.
10. Remove rear bracket bolts, rear bracket and O-rings.
11. Remove wave washer.
12. Remove front side plate, cam ring, rotor, vane plates and rear side plate as follows:
a. Using extension bar and press, remove front side plate, cam ring, rotor, vane plates and rear side plate as an assembly. Do not allow components to fall from under side of pump when pressing out of housing.
b. Remove rear side plate and O-ring.
c. Remove cam ring, rotor and the ten vane plates.
d. Remove straight pin and two O-rings from front side plate.
e. Remove straight pin from front housing.

Inspection

1. Measure oil clearance of shaft and bushing using suitable measuring tools. Maximum clearance is .0028 inch.
2. Inspect rotor and vane plates using suitable measuring tools. Minimum height is .315 inch, minimum thickness is .0697 inch and minimum length is .5894 inch.

Fig. 2 Power Steering System Rotor & Cam Ring Identification Marks:

Fig. 10 Rotor & Cam Ring Identification Chart:

3. Using suitable feeler gauge, measure clearance between the rotor groove and vane plate. Maximum clearance is .0012 inch. If clearance is not as specified, replace vane plate and/or rotor with one having the same mark stamped on the cam ring, Figs. 2 and 10.
4. Inspect flow control valve as follows:
a. Coat valve with power steering fluid and ensure it falls smoothly into valve hole by its own weight.
b. Close one of the holes and apply 57-71 psi compressed air into opposite side and confirm that air does not come out from end holes.
c. If necessary, replace valve with one having the same letter as inscribed on front housing (A through F).
5. Measure the flow control spring free length. If spring free length is not 1.42 inches, replace spring.
6. Using a hammer and special service tool No. 09631-10030 or equivalent, tap out oil seal.
7. Using a 22mm socket and hammer, drive in new oil seal.
8. Remove bearing retainer snap ring with snap ring pliers.
9. Use a press to remove old bearing and to install new bearing, then replace snap ring.

Assembly
1. Coat all sliding surfaces with power steering fluid prior to assembly.
2. Using a press and special service tool No. 09238-47012 or equivalent, press in the vane pump shaft and bearing.
3. Install the snap ring.
4. Install long straight pin into front housing.
5. Coat new O-ring with power steering fluid and install on front and rear side plates.
6. Align wide hole on front side plate with straight pin, then using special service tool No. 09238-47012 or equivalent, press front side plate into housing. Use care not to damage O-rings.
7. Install shorter straight pin into front side plate.
8. Align wide hole of cam ring with long straight pin then install the cam ring with the inscribed mark facing the rear.
9. Install rotor to shaft with inscribed mark on rotor facing toward the rear.
10. Install ten vane plates with found end facing outward.
11. Align wide hole with long straight pin and press in rear side plate with a suitable press.
12. Install wave washer so its protrusions fit into slots in rear side plate.
13. Coat new O-ring with fluid and install on rear bracket.
14. Install rear bracket and four bolts. Torque bolts to 29 ft. lb.
15. Measure pump shaft preload as follows:
a. Ensure shaft rotates smoothly without abnormal noise.
b. Temporarily install pulley nut and check rotational torque. Rotating torque should be .9 in. lb. or less.
16. Install flow control valve, spring, spring seat and pressure port union as follows:
a. Coat new O-ring with fluid and install on the spring seat and pressure port union.
b. Insert spring seat with bolt hole facing outward.
c. Using suitable snap ring pliers, install snap ring.
d. Install spring and valve into housing then the pressure port union. Torque pressure port union to 51 ft. lb.
17. Install new O-ring to suction port union, then install suction port union and torque bolts to 9 ft. lb.
18. Install pump pulley and nut to shaft. Using special service tool No. 09278-54012 or equivalent, torque set nut to 32 ft. lb.