How to change a power steering pump on a 1999 Ford Expedition?

Answer 1

You must first remove the fan and shroud assembly to fit the pulley removal tool. Then remove the belt. Install pulley removal tool and press off the Power Steering pulley. Remove the pressure and return lines and the pump mounting bolts. Now you could press the pulley on the new pump at this time but it makes for a difficult reinstall of the pressure line due to its position near the pulley. I prefer to install the new pump and reconnect the pressure and return lines. Be sure to replace the neoprene seal on the pressure line. If you heat it in a cup of hot water it is much easier to expand the seal over the pressure line threads. I also expand the seal by sliding it over a tapered punch and stretching it slightly, when it cools it shrinks down slightly so if you do it fast it will all work out ok. Once the lines are back on and the evo (electronic variable orifice) actuator is plugged back in you can press the pulley back on. Make sure the pump shaft is flush with the pulley hub when you are finished pressing or belt misalignment will occur. In other words make sure the pulley is pressed all the way on the shaft (pressing the pulley on takes a lot of force and is not easy). Now reinstall the belt, fan and shroud. Now refill the power steering reservoir with approved fluid and make sure the reservoir level does not fall below the return hose level or air will get into the system and will take some time to bleed out. Usually I have a helper top off the reservoir at startup because that's when the pump pressurizes the system and the level in the reservoir drops. You will hear a power steering pump moan briefly at startup due to the pump being started empty but this noise will immediately disappear as long as the reservoir level does not drop below the return hose level. At this point you are done. Good luck.

You don't need to remove the pulley. You can get to the bolts using a ratcheting wrench, and or a socket and swivel. Some bolts can be reached through the drivers side wheel well, with the wheel off.