Good Times
02-22-2009, 06:42 PM
This will be in the wiki as soon as I get a chance to convert it but for the time being here's the "how to" part :)
This is a rebuild of a 2003 4runner V8 Power Steering pump. The power steering pump is also found in the 98-07 Tundra (v8), 98-07 LandCruiser (v8), 03-09 GX (v8), 03-09 4runner (v8): any Toyota 4.7L V8 power steering pump as applicable.
Tools Needed:
Screwdriver
12mm, 14mm, 17mm, 24mm Sockets, socket wrenches
12mm, 14mm, 17mm, 24mm Box wrenches
Snap-ring pliers (optional)
Pliers (optional)
Press
Torque wrench
Vise
Vernier Caliper
Parts/Supplies Needed:
Gasket Kit (power steering pump) #04446-06040
Shop towels, rags
ATF oil
1.) Remove the pump pulley. (17mm socket and getting creative by using a box wrench to counter the pulley). When you are using a vice to hold down the pump, do not latch it down too tight as you may damage the housing.
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6709.jpg
2.) Remove the four 14mm bolts holding the power steering pump housing together.
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6710.jpg
3.) Once you open the pump you will find a cylindrical unit with a bunch of fins. DO NOT LOSE ANY OF THOSE!!!
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6711.jpg
Look at the center of the bolt and you will find a c-clip. Remove this clip.
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6712.jpg
The removed bolt should look like this:
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6713.jpg
4.) Close the housing back up as you need to flip the unit to remove the bolt and the outer pump housing seal. I say this because it'll take a bit of give using the vice to hold down the pump housing so instead of trying to do it with the internals exposed it's much safer to close the pump. Flip the pump upside down and expose the pump housing seal.
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6717.jpg
5.)Using a flathead screwdriver remove the seal as shown.
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6718.jpg
6.) While you're working on the outside remove two input and output lines. You'll need to replace both o-rings.
This one requires a 12mm socket.
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6719.jpg
The o-ring looks like this.
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6720.jpg
The other one requires a 24mm socket.
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6721.jpg
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6722.jpg
Replace this o-ring too.
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6723.jpg
7.) Once that is removed, remove the flow control valve. You will find a spring inside so make sure to get that out too.
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6724.jpg
Inspect the spring to make sure the length is still to factory setting. Minimum free length: 33.2mm (1.307in)
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6736.jpg
If you're an idiot like me and forget to calibrate your caliper, you end up with a result like this! :loser:
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6734.jpg
8.) Open up the pump again and remove the metal gasket.
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6714.jpg
9.) Carefully remove the center vane pump rotor. Ensure that none of the fins fall out. If you lose any of those, you're pretty much toast :)
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6716.jpg
10.) Remove the vane pump cam ring plate (looks like a big fat cylindrical ring).
11.) Look at the backside of the pump and remove the plate.
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6725.jpg
12.) Remove and replace o-ring.
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6726.jpg
13.) Notice this wave washer? It's suppose to be like this so don't freak out! (or that's what the FSM says... "wave washer"). Don't worry I freaked out when I saw it too.
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6727.jpg
Another picture showing what it looks like on the vane pump housing rear.
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6728.jpg
14.) Remove and replace o-ring.
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6729.jpg
15.) New o-ring. :)
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6730.jpg
16.) Reinstall vane pump cam ring plate (the big fat cylindrical ring).
17.) Reinstall center vane pump rotor. (Make sure none of the fins disappear on ya!)
18.) Install the vane pump housing rear with the wave washer.
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6732.jpg
19.) It should look like this once you add everything back together. Also install new metal gasket.
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6733.jpg
20.) Reinstall pulley bolt and install new c-clip.
21.) Close her up!
22.) Flip the housing and install the vane pump housing oil seal.
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6740.jpg
23.) You can use a press or use a 24mm socket and carefully press it in.
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6709.jpg
On a related note, I found out how hard these pumps actually work. 8,336 kPa (85 kgf/cm2, 1,209 psi) under minimum load. Not sure what figures are thrown out under maximum load! :tapedshut:
This is a rebuild of a 2003 4runner V8 Power Steering pump. The power steering pump is also found in the 98-07 Tundra (v8), 98-07 LandCruiser (v8), 03-09 GX (v8), 03-09 4runner (v8): any Toyota 4.7L V8 power steering pump as applicable.
Tools Needed:
Screwdriver
12mm, 14mm, 17mm, 24mm Sockets, socket wrenches
12mm, 14mm, 17mm, 24mm Box wrenches
Snap-ring pliers (optional)
Pliers (optional)
Press
Torque wrench
Vise
Vernier Caliper
Parts/Supplies Needed:
Gasket Kit (power steering pump) #04446-06040
Shop towels, rags
ATF oil
1.) Remove the pump pulley. (17mm socket and getting creative by using a box wrench to counter the pulley). When you are using a vice to hold down the pump, do not latch it down too tight as you may damage the housing.
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6709.jpg
2.) Remove the four 14mm bolts holding the power steering pump housing together.
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6710.jpg
3.) Once you open the pump you will find a cylindrical unit with a bunch of fins. DO NOT LOSE ANY OF THOSE!!!
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6711.jpg
Look at the center of the bolt and you will find a c-clip. Remove this clip.
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6712.jpg
The removed bolt should look like this:
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6713.jpg
4.) Close the housing back up as you need to flip the unit to remove the bolt and the outer pump housing seal. I say this because it'll take a bit of give using the vice to hold down the pump housing so instead of trying to do it with the internals exposed it's much safer to close the pump. Flip the pump upside down and expose the pump housing seal.
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6717.jpg
5.)Using a flathead screwdriver remove the seal as shown.
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6718.jpg
6.) While you're working on the outside remove two input and output lines. You'll need to replace both o-rings.
This one requires a 12mm socket.
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6719.jpg
The o-ring looks like this.
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6720.jpg
The other one requires a 24mm socket.
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6721.jpg
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6722.jpg
Replace this o-ring too.
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6723.jpg
7.) Once that is removed, remove the flow control valve. You will find a spring inside so make sure to get that out too.
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6724.jpg
Inspect the spring to make sure the length is still to factory setting. Minimum free length: 33.2mm (1.307in)
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6736.jpg
If you're an idiot like me and forget to calibrate your caliper, you end up with a result like this! :loser:
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6734.jpg
8.) Open up the pump again and remove the metal gasket.
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6714.jpg
9.) Carefully remove the center vane pump rotor. Ensure that none of the fins fall out. If you lose any of those, you're pretty much toast :)
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6716.jpg
10.) Remove the vane pump cam ring plate (looks like a big fat cylindrical ring).
11.) Look at the backside of the pump and remove the plate.
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6725.jpg
12.) Remove and replace o-ring.
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6726.jpg
13.) Notice this wave washer? It's suppose to be like this so don't freak out! (or that's what the FSM says... "wave washer"). Don't worry I freaked out when I saw it too.
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6727.jpg
Another picture showing what it looks like on the vane pump housing rear.
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6728.jpg
14.) Remove and replace o-ring.
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6729.jpg
15.) New o-ring. :)
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6730.jpg
16.) Reinstall vane pump cam ring plate (the big fat cylindrical ring).
17.) Reinstall center vane pump rotor. (Make sure none of the fins disappear on ya!)
18.) Install the vane pump housing rear with the wave washer.
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6732.jpg
19.) It should look like this once you add everything back together. Also install new metal gasket.
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6733.jpg
20.) Reinstall pulley bolt and install new c-clip.
21.) Close her up!
22.) Flip the housing and install the vane pump housing oil seal.
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6740.jpg
23.) You can use a press or use a 24mm socket and carefully press it in.
http://www.chaosedition.com/photogallery/images/misc/Power%20Steering%20Pump%20Rebuild/IMG_6709.jpg
On a related note, I found out how hard these pumps actually work. 8,336 kPa (85 kgf/cm2, 1,209 psi) under minimum load. Not sure what figures are thrown out under maximum load! :tapedshut: