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Assembly - Pump (Pulley)

WARNING: This page is about a different car, the 2004 Dodge Intrepid, 2004 Chrysler Intrepid, 2004 Chrysler Concorde, and 2004 Chrysler 300M. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Do not press or hammer on the shaft of the power steering pump in an attempt to install the pulley. This will damage the internal components of the power steering pump.
  1. Place the power steering pump pulley on the end of the power steering pump shaft. Make sure the pulley is installed squarely on the end of the shaft.
    Fig 1: Power Steering Pump Pulley Removal
    G03499543Courtesy of DAIMLERCHRYSLER CORP.
    CAUTION: When installing the pulley on the power steering pump, Spacer, Special Tool 6936, MUST be used. The spacer provides for the correct pulley location on the power steering pump to provide correct accessory drive belt alignment. The alignment is critical in controlling accessory drive belt noise. It also prevents the pulley from contacting the power steering pump when it is installed, causing power steering pump or pulley damage.
  2. Install Spacer, Special Tool 6936, into the hub of the power steering pump pulley (Fig 2 ).
    Fig 2: Spacer installed In Power Steering Pump Pulley
    G03499544Courtesy of DAIMLERCHRYSLER CORP.
  3. Insert the Pulley Installer, Special Tool C-4063, (without adapters) through hole in spacer. Thread the Installer into the end of the power steering pump shaft (Fig 3 ). Tighten the installer into pump shaft.
  4. Holding the Pulley Installer with one wrench so it will not rotate, turn hex nut down threaded rod of installer pushing the pulley onto the shaft of the power steering pump (Fig 3 ). Ensure that the tool and the pulley remain aligned with the pump shaft so pulley does not become cocked on shaft.
    Fig 3: Installing Power Steering Pump Pulley
    G03499545Courtesy of DAIMLERCHRYSLER CORP.
  5. Continue to push pulley onto shaft of power steering pump until Pulley Installer will no longer turn. This will ensure the spacer provided is fully seated against the front of the power steering pump shaft.
  6. Remove the Pulley Installer from the shaft of the power steering pump. Remove the Spacer from the hub of the power steering pump pulley.
  7. Verify the pulley turns properly on the pump shaft.
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