Power Steering Pump: Reassembly

Place rotor onto rotor shaft splines, with large counterbore of rotor facing upward. Install retaining ring in rotor shaft groove. Place cam insert over rotor with recessed flat facing toward reservoir.
If rotor and cam assembly were disassembled, hold rotor half way out of cam, and insert spring into rotor spring pocket. Use a slipper to compress spring. Install slipper with narrow groove facing cam. Slippers must be installed with narrow groove rail spacing facing cam, otherwise pump will not function.
Hold cam stationary. Turn rotor one space at a time, and install all 10 rotor springs and slippers. Ensure springs and slippers do not fall out when turning rotor.
Using a plastic mallet and Seal Driver (T78P-3733-A3), install a new rotor shaft seal in housing by driving seal and then seal retainer into bore until bottom. Turn pump housing over, and position pump housing plate on a flat surface with pulley/seal side down. See Figure .
Insert 2 dowel pins and disc spring (dished surface upward) into housing plate. Lubricate lower pressure plate "O" ring seals with power steering fluid. Install seals to lower pressure plate.
Insert lower pressure plate, with "O" ring seals toward front of pump, into bottom of pump housing plate and over dowel pins. Place pump housing plate assembly into "C" clamp using lower support plate on pump rotor shaft to protect new seal. See Figure . Place Driver (T78P-3733-A3) in center rotor shaft hole.
Tighten "C" clamp until lower plate lightly bottoms in pump plate housing. This operation will seat lower pressure plate "O" ring. Install cam/rotor assembly (cam, rotor, slippers, and rotor shaft) into pump housing plate, over dowel pins.
NOTE: When installing cam/rotor assembly, stepped holes must be used for dowel pins. Recessed notch in cam insert must face reservoir and be about 180° opposite square pump mounting boss.
Place upper pressure plate over dowel pins. Side of plate with square recessed notch must face reservoir end and be positioned 180 degrees opposite the pump's square mounting boss. Place new "O" ring seal on valve cover. Lubricate with power steering fluid.
NOTE: Ensure plastic baffle is securely in place in valve cover. If not, apply petroleum jelly to baffle. Install baffle.
Place valve cover over dowel pins. Ensure valve cover outlet fitting hole is directly in line with square mounting boss of pump housing plate.
Place entire pump housing assembly in "C" clamp. Install upper compressor plate to valve cover. Tighten "C" clamp to compress valve cover into pump housing plate until retaining ring groove in pump housing plate is exposed.
Install valve cover retaining ring with ends near access hole in pump housing plate. See Figure . Remove pump assembly from "C" clamp. Place new large "O" ring seal on outside of pump housing plate. Lubricate "O" ring seal with power steering fluid. Install power steering reservoir to pump housing, aligning outlet fitting hole in reservoir with threaded fitting hole in valve cover. See Figure .
Install flow control spring and flow control valve into valve cover. Place new "O" ring seals on outlet fitting. Lubricate seals with power steering fluid.
Install pump outlet fitting into valve cover. Tighten fitting to specification. See TORQUE SPECIFICATIONS .

CAUTION: When clamping pump cast iron housing in vise, be careful not to exert excessive force on front hub or pump. Hammering on ANY pump components during assembly/disassembly may cause damage.

Lubricate all "O" rings, seals and seal surfaces with power steering fluid or petroleum jelly. With pump on flat surface, drive new shaft seal in until it bottoms on bore shoulder.
Clamp pump housing in vise with shaft pointing down. Install dowel pins. Install thrust plate on shaft with ports toward splined end of shaft. Slide rotor over shaft splines, with counterbored end toward thrust plate. Install new rotor retaining ring to shaft. Ensure ring is seated in groove.
Install a new retaining ring on splined end of shaft by prying ring open and sliding down shaft until seated in ring groove. Install cam ring on dowels with rotation arrow toward rear of housing. Install vanes in rotor slots, with rounded edge of vane facing out, toward cam ring inner surface. Vanes should slide freely in rotor.
Lubricate pressure plate with power steering fluid. Position pressure plate on dowel pins with circular spring depression facing rear of housing. Narrow slots in plate should engage dowel pins. Press down on socket with both thumbs to seat plate assembly over "O" ring in pump housing bore. Lubricate end plate "O" ring with power steering fluid and install in second groove from end of housing.
Place pressure plate spring in groove in pressure plate. Lubricate end plate with power steering fluid. Place end plate over spring. Using thumb pressure or arbor press, press end plate down to just slightly below retaining ring groove. Install retaining ring in groove. Use care to prevent cocking end plate in bore or distorting assembly. Release pressure on end plate.
Using a punch, tap retaining ring ends around in groove until opening is opposite flow control valve bore. This ensures maximum retention of retaining ring. Install flow control valve spring in hole. Install flow control valve assembly with screened end toward front of housing.
Install new large "O" ring to outside of pump housing. Install "O" ring seals to countersunk holes for mounting studs and flow control valve. Lubricate inside edge of reservoir, and install reservoir onto pump housing, aligning mounting stud holes. Install studs and snug tighten.
If necessary, tap reservoir down on pump housing using a soft-faced hammer. Install new "O" ring on pressure union groove next to hex head of fitting.
CAUTION: DO NOT install "O" ring in lower groove on pressure union fitting. This will restrict relief outlet orifice.
Install pressure union fitting to pump housing and tighten to 11-16 ft. lbs. (15-22 N.m). Tighten mounting studs to 35 ft. lbs. (47 N.m). Remove pump from vise. Install mounting bracket and pulley. See POWER STEERING PUMP under REMOVAL & INSTALLATION.