Hello, again. Haven't been here since working on my son's Bronco E4OD, and that's probably my bad...

My 96 Explorer has had a leak in the PS (rack right end, actually) for several years, and kept putting it off, topping the fluid, etc. Last week, the rack began a tight binding, so decided to fix it. Replaced the rack, and since the pump had several instances of running dry over the years, for the money intended to change it also. All parts from Autozone, BTW.

The pulley (with a proper hub puller) would NOT budge. As a last-ditch effort, since the mounting bolts will not come out with the pulley in the way, I even tried torching the hub, but it still would not pull off.

So, went back to get a new pulley, destroyed the old one, replaced the pump, and the NEW pulley will not install (using the supplied 3/8-16 grade 5 bolt to pull it onto the shaft. With about 3/8" still to go, the bolt is jumping thread in the shaft! No metal has shaved from either the bolt or the internal threads, it is as if the internal thread is slightly oversize. That's not to say that it isn't applying force, for I was fearful of twisting the grade 5 bolt before the threads would slip.

Before starting the install, I carefully checked and found no burrs on either new pulley or new shaft. I applied a light film of clean grease.

Any insight?

Thanks!

Since I found no similar post, I assume most of you never have this problem...

 

I have no personal experience with this, but I came across this tool
http://www.etoolcart.com/browseproducts/Ford-Power-Steering-Pump-Pulley-Installer-----OTC7771.HTML
and thought it may help. Good luck!

 

Thanks for the reply. I bought a new KD-Tools puller/installer set, 100 bucks at NAPA, but was in better shape and design than the rental tool was using. Plus, when I pulled the new pulley back off, I chucked it in my lathe, and emoried the bore slightly, and champhered the entrance a tad.

It was still a mighty tough push, but the KD tool was up to it, and so, thank goodness, were the threads in the pump shaft. Didn't have the problem of slipping threads, so I guess the best advice is ... "Don't even try the grade-5 bolt they give with the pulley as an installer!"