C3 Shark Tank

everything you need to know

The Power Steering Pump

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To rebuild the pump, start by cleaning it in a non-toxic solvent. It is much earier to work on a clean part than a greasy one. Mount the pump in a vise while taking care not to distort the front hub of the pump. Use a 7/8 and 15/16-inch wrench to remove the pulley retaining nut.

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Use a pulley remover, which can be rented from a tool rental shop, to remove the pulley. Also remove or keep track of the alignment key.

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After the pulley is off and set aside, you can remove the union and seal.

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Remove the reservior retaining studs. Keep track of which stud went where.

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The reservoir can now be seperated from the housing. Place the plate on the dowel pins with the ported face toward the pump ring. Set the pressure plate by placing a large socket on top of the plate and pushing down with your hand.

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The mounting bolt O-rings and the union O-rings can now be removed.

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Remove the end plate retaining ring by compressing it: Insert a small punch in the 1/8″ diameter hole in the housing and push it in until the ring clears the groove. You can now insert a screwdriver and pry the ring out.

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Remove the shaft woodruff key and tap the end of the shaft with a dead-blow hammer to free the pressure plate, pump ring, rotor assembly and thrust plate. Remove these parts as one unit.

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Now remove the end plate O-ring. Check the shaft for wear, look into the housing for scour marks and check the housing and reservoir for cracks. Make sure all parts are clean for reassembly.

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To remove the old shaft seal, insert a wide-blade screwdriver and gently pry it out of the housing.

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Use a seal installer or socket and hammer to seat the new shaft seal into the housing. Now re-install the pressure plate, pump ring, rotot assembly and thrust plate.

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Lubricate the outside diameter and chamfer of the pressure plate with petroleum jelly to avoid damaging the new O-ring.

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Place the plate on the dowel pins with the ported face toward the pump ring. Set the pressure plate and pushing down with your hand.

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The end plate spring, new O-ring and end plate can be installed next. Be sure to lubricate the end plate O-ring with petroleum jelly to stop damage. Re-install the end plate retaining ring. (This sometimes take two people.) Be sure the ring is in the groove and the ring gap is positioned properly. Also install the new mounting bolt O-rings and the new union O-ring.

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Now install the flow control spring and plunger with the hexhead screw end in the bore first.

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Place the reservoir in its normal position and press it down until the reservoir sits on the housing. Check the position of the stud seals and the union seal. Reinstall the reservoir retaining studs, then place a new O-ring on the union and replace it.

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The woodruff key can now be reinstalled.

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Slide the pulley into place and reinstall the retaining nut. When the pump is reinstalled on the car, it will have to be bled. To do this, first connect all of the hose fittings. Now fill the reservoir. Bleed the pump by turning the pulley backward (counterclockwise as viewed from the front of the car) until all of the air bubbles disappear. If the system has been drained, you will have to keep refilling the reservoir as it fills the system. Once the system has been bled, install the belt and tighten it to specs.

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This is the power steering system completely rebuilt and ready to run with no more drips.