Disassembly and Assembly

Disassembly

1. Remove power steering pump.
2. Mount pump in a suitable vise.

Fig. 3 Exploded View Of Power Steering Pump:

3. Using special service tool No. 09616-30020 or equivalent, remove the pulley nut and pulley, Fig. 3.
4. Using special service tool No. 09612-24014 or equivalent, remove control valve, then remove O-rings from control valve and rear housing.
5. Remove three suction port union bolts, union and O-rings.
6. Remove power steering pressure port union and O-ring.
7. Remove power steering flow control valve and spring.
8. Remove hydraulic cooling fan pressure port union and O-ring.
9. Remove hydraulic cooling fan flow control valve and spring.
10. Remove four bolts rear housing and gasket.
11. Remove hydraulic cooling system cam ring, rotor, and vane plates.
12. Remove front side plate and two rear side plates.
13. Remove power steering system cam ring, rotor, and vane plates.
14. Put each straight pin in a vise and rotate housing to pull straight pin from housing.
15. Using snap ring pliers, remove snap ring.
16. Using a suitable plastic hammer, tap out pump shaft.
17. Install a bolt and flat washer to rear plate and using special service tool No. 09910-00015 or equivalent, remove rear plate.
18. Remove two O-rings from rear side plate and remove wave washer.

Inspection

1. Measure oil clearance of shaft and bushing using suitable measuring tools. Maximum clearance is .0020 inch.
2. Inspect rotor and vane plates for power steering system using suitable measuring tools. Minimum height is .339 inch, minimum thickness is .055 inch and minimum length is .5904 inch.
3. Inspect rotor and vane plates for hydraulic cooling fan system using suitable measuring tools. Minimum height is .319 inch, minimum thickness is .071 inch and minimum length is .5898 inch.

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

Fig. 4 Power Steering System Rotor & Cam Ring Identification Chart:

4. Using suitable feeler gauge, measure clearance between the rotor groove and vane plate for power steering system. Maximum clearance is .0014 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 4.

Fig. 5 Hydraulic Cooling Fan System Rotor & Cam Ring Identification Marks:

Fig. 6 Hydraulic Cooling Fan System Rotor & Cam Ring Identification Chart:

5. Using suitable feeler gauge, measure clearance between the rotor groove and vane plate for hydraulic cooling fan system. Maximum clearance is .0014 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. 5 and 6.
6. 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).
7. Measure the flow control spring free length. If spring free length is not 1.46-1.54 inch, replace spring.
8. Using special service tool No. 09631-10030 or equivalent, drive out oil seal.
9. Using a 24mm socket and a hammer, drive in new oil seal.
10. Using a press, remove ball bearing from pump shaft, then using a deep 17 mm socket and a press, install new ball bearing to pump shaft.

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, install pump shaft with ball bearing.
3. Install snap ring with snap ring pliers.
4. Using a suitable plastic hammer, tap in two straight pins.
5. Install cam ring, rotor, and vane plates for power steering system.
6. Install front side plate and two rear side plates.
7. Install cam ring, rotor, and vane plates for hydraulic cooling fan system.
8. Install rear side plate and wave washer.
9. Install new gasket to rear housing, then install rear housing and torque bolts to 34 ft. lb.
10. Ensure shaft rotates smoothly without abnormal noise, then install pulley nut and check rotating torque. Rotating torque should be 2.4 in. lb. or less.
11. Install hydraulic cooling system flow control valve and pressure port union with new O-ring. Torque pressure port union to 62 ft. lb.
12. Install power steering system flow control valve and pressure port union with new O-ring. Torque pressure port union to 62 ft. lb.
13. Install suction port unions with new O-rings. Torque bolts to 9 ft. lb.
14. Install new O-rings to rear housing and control valve, then using special service tool No. 09612-24014 or equivalent and torque wrench with a 13.39 inch fulcrum, install control valve.
15. Install pump pulley to shaft, then install set nut. Torque nut to 32 ft. lb.
16. Install steering pump.