Pump

The following precautions must be observed when servicing the power steering pump (3A674) :

1. Use a clean work bench and tools.

2. Thoroughly clean the exterior of the power steering pump with solvent. Drain as much fluid from the power steering pump as possible.

3. If only the power steering oil reservoir (3A697) is to be removed, clean as outlined.

4. Do not use cleaning solvents on the seal.

Disassembly

1. Remove the power steering pump pulley (3A733) as outlined.

2. Remove the power steering pump valve outlet fitting (3D654) , power steering pump valve (3A561) , and power steering pump flow control valve spring (3D586) from the power steering pump , and remove the power steering oil reservoir as outlined.

3. Place C-Frame and Clamp Assembly T74P-3044-A1 in a bench vise.

4. Place the Lower Support Plate T78P-3733-A2 over the power steering pump rotor shaft (3B559) .
   
   
   
   

5. Install the Upper Support Plate T78P-3733-A1 into the upper portion of the C-clamp.

6. Holding the upper Support Plate, place the power steering pump assembly into the C-clamp with the power steering pump rotor shaft facing down.

7. Tighten the C-clamp until a slight bottoming of the valve cover is felt.
   
   
   
   

8. In the side of the power steering pump housing is a small hole. Through this hole, insert a small drift or suitable tool and push inward on the valve cover retaining ring. While applying inward pressure on the retaining ring, place screwdriver under the edge of the retaining ring, and remove the ring.
   
   
   
   

9. Loosen the C-clamp. Remove the upper power steering pump pressure plate (3D590) and remove the power steering pump assembly.

10. Remove the pump valve cover. Discard the o-ring seal (9229) .

11. Push on the power steering pump rotor shaft to remove the power steering pump rotor shaft , upper power steering pump pressure plate , power steering pump rotor (3D607) assembly and two dowel pins.
    
    
    
    
    

    Item	Part Number	Description
    1	3C544	Power Steering Valve Input Shaft Cap
    2	3D590	Power Steering Pump Pressure Plate (2 Req'd)
    3	3D607	Power Steering Pump Rotor
    4	387579-S	Dowel Pin (2 Req'd)
    5	3D643	Power Steering Pump Plate and Bushing

12. The lower power steering pump pressure plate and the power steering pump pressure plate spring (3D596) will remain in the power steering pump housing (3A643) . To remove, place the power steering pump housing on a flat surface. Raise slightly and strike the housing against flat surface until the lower power steering pump pressure plate and the power steering pump pressure plate spring fall out. Discard the o-ring seals .
    
    
    
    

13. Remove the rotor shaft seal and seal retainer ring simultaneously by prying out with a screwdriver.
    
    
    
    

Assembly

If the rotating group was disassembled for cleaning and inspection, assemble as follows:

1. Place the rotor on the rotor shaft splines. Rotor is symmetrical, so it can be installed either way.

2. Install the retaining ring in the groove at the end of the power steering pump rotor shaft .

3. Place the insert cam over the rotor. Ensure that the recessed notch on the insert cam faces up.
   
   
   
   

4. With the rotor extended upward, approximately half-way out of the cam, insert a spring into a rotor spring pocket. Work in the rotor cavity directly beneath the recessed flats on the cam.
   
   
   
   

5. Use one of the slippers to compress the spring, and install the slipper with the groove facing the cam profile. Repeat Steps 4 and 5 on the slipper cavity beneath the opposite inlet recess.
   
   
   
   

6. Holding the cam stationary, index the rotor either right or left one space, and install another spring and slipper until all 10 rotor cavities have been filled. Turn the rotor carefully, so that the springs and slippers already installed do not fall out.
   
   
   
   

7. Install the rotor shaft seal using Seal Driver T78P-3733-A3. Using a plastic mallet, drive the seal into the bore until a bottoming is felt. Install the seal retainer in the same manner.
   
   
   
   

8. Place the power steering pump housing on a flat surface with the pulley side facing down.

   NOTE: The power steering pump pressure plate spring must be inserted with the dished surface upward.

9. Insert the two dowel pins and the power steering pump pressure plate spring into the power steering pump housing .
   
   
   
   

10. Lubricate the inner and outer o-ring seals with the specified power steering fluid. Install these seals on the lower power steering pump pressure plate .
    
    
    
    

11. Insert the lower power steering pump pressure plate with the o-ring seals toward the front of the pump into the power steering pump housing and over the dowel pins.
    
    
    
    

12. Place the entire assembly on the C-clamp, T74P-3044-A1. Place Seal Driver T78P-3733-A3 into the rotor shaft hole, and press on the lower power steering pump pressure plate lightly, until it is felt to bottom into the power steering pump housing . This operation will seat the outer o-ring seal .
    
    
    
    
    
    
    
    

    NOTE: When installing this assembly into power steering pump housing , the stepped holes must be used for the dowel pins, and the recessed notch in the cam insert must face toward the power steering oil reservoir and approximately 180 degrees opposite the square mounting lug on the aluminum housing. Refer to illustration under Assembly, Step 3.

13. Install the cam, rotor and slippers, and rotor shaft assembly into the power steering pump housing over the dowel pins.

14. Place the upper power steering pump pressure plate over the dowel pins with the recess directly over the recessed notch on the cam insert and approximately 180 degrees opposite the square mounting lug.
    
    
    
    

    NOTE: Ensure plastic baffle is placed securely in the valve cover. If the baffle is loose, apply a coating of petroleum jelly on the baffle, and install it into location on the valve cover.

15. Place a new o-ring seal on the valve cover. Lubricate this seal with the specified power steering fluid.
    
    
    
    

16. Insert this valve cover over the dowel pins. Ensure the outlet fitting hole in the valve cover is directly in-line with the square mounting lug of the aluminum housing.
    
    
    
    

17. Place the entire assembly in the C-clamp tool, and compress the valve cover into the power steering pump housing , until the retaining ring groove is exposed in the power steering pump housing .

18. Install the valve cover retaining ring with the ends near the access hole in the power steering pump housing .
    
    
    
    

19. Remove the power steering pump assembly from the C-clamp tool.

20. Place a new o-ring seal on the power steering pump housing . Lubricate this o-ring seal with the specified power steering fluid.

21. Install the power steering oil reservoir .

     CAUTION: If the power steering pump valve is cocked, it may become stuck in the power steering pump housing . Do not force the power steering pump valve forward; forcing the power steering pump valve may shear off metal and carry the metal chips into the valve bore.

22. Install the power steering pump flow control valve spring and the power steering pump valve into the power steering pump housing .

23. Place new o-ring seals on the power steering pump valve outlet fitting . Lubricate these seals with the specified power steering fluid.

24. Install the power steering pump valve outlet fitting into the valve cover. Tighten to 34-46 Nm (25-34 lb-ft).

25. Install power steering pump pulley as outlined.