How do you replace a power steering pump on a 98 Plymouth voyager?

Answer 1

THIS WAS DONE ON A 98 Dodge Caravan 2.4L motor, similar to Plymouth Voyager (which I own also) tools: metric and standard wrenches and sockets 15mm, 1/2", 18mm I think... if you have a whole set, no problem (sorry I can't remember the sizes) **secure the front of the car on jack stands with the parking brake on** 1. disconnect the battery 2.remove the v-belt and Power Steering belt... loosen the alternator tensioner bolt and the pivot bolt (on bottom) ...use a ratchet to loosen the alternator enough to get the belt off. 3. Drain as much fluid as you can from the P/S reservoir.. (where you fill it) w/ a turkey baster or a spray bottle trigger (put the straw in and squirt into a bottle) 4. Disconnect the hoses from the pump...fluid can leak from the pump and hoses, so make sure you have a large pan or basin to catch excess fluid! (The nipple for the return line is built-in to the pump; remove the hose clamp & hose.) plug the lines/ holes in pump to keep the fluid from going everywhere. 5.There is a tensioner nut on the driver's side where you can't see it... you MUST loosen it, AND the bolt on the passenger side of the tensioner AND the bolt on the BOTTOM power steering pump bracket-DON'T remove the Bottom bolt-loosen it slightly. (go under the car for the bottom bolt) --the nut/bolts on the tensioner will allow it to slide; the bottom bolt being loose allows the pump to pivot LIKE the alternator. Remove the P/S belt. 6. Remove the 3 bolts holding the pump to the bracket. On this model, you can remove the pump from the top --be careful not to break the pulley!! ( I did when it slipped) The pulley is made from high-density plastic, not metal. Get a replacement pump -Ask for one WITH the reservoir- this is the housing that goes on the pump, NOT the reservoir for your fluid...otherwise, you'll have to almost rebuild your pump! Noone will tell you all this until it's too late! ( preferably from a parts store) compare the old and new pumps... make sure they are the same...just like a replacement pulley; unless you find one at a junkyard the pumps WON'T be identical! 7. Rent a jaw puller from the parts store, because the pumps don't come with the pulley... follow the instructions! -Install the pulley on the new pump- I did this by using a bolt and washer that you tighten down until the pulley goes on. make sure the pulley is flush on the outside. [[the original pumps will have a stud where you will need to place a bolt, and some washers-- ***if you don't use washers, your pump will be crooked and all the work you did will be for nothing!!*** -line up the pump by installing the bolts to the bracket and all the bolts except the one nut for the driver's side. Measure from the outside of the pump to the outside of the bracket... add 3/8" ... get washers for the space between the pump and bracket. the thread you'll need is the same as the other bolts that hold the pump in place. use a string to lower the washers into place while the bolt goes thru the bracket and washers into the pump. this all goes where you had to loosen the nut that you couldn't see earlier. (this is what a mechanic will have to do to get it in... the part where he charges you a ton of labor but doesn't say why, because it will take him all day to figure it out) 8. Make sure you install a new O-Ring on the pressure line, or it will leak (COMES W/ THE PUMP) install a filter on the return hose to catch any dirt still in the system. -fit the hoses and everything back together, opposite of removal. 9. replace the belts- tension -1/4" between 2 pulleys 12" or less - 1/2" play when the center of the pulleys is more like 15" when you put about 10 lbs pressure with your thumb. 10. fill the reservoir with P/S fluid 11. lower the car, connect the battery and start it up- work the steering back and forth almost all the way repeatedly, and MAKE SURE THE RESERVOIR DOES NOT GET EMPTY..OR YOUR PUMP WILL BURN OUT! this will work the air out of the system, when the pump stops sucking in fluid make sure it is at the right level. I suggest you get a Haynes manual- # 30011 It will tell you most of this, especially some specifications but really what I put is what will happen. it can also help you by showing diagrams of other motors..ie:3.0L, 3.3L, etc. on other motors, you may have to take the pump out from under the car. Sorry I could not put all the details, I hope I didn't leave anything out and I hope this will help anyone! good luck! -Scoot Deezel