91 power steering pulley install problem

[91 red explorer]

I replaced my power steering pump over the weekend and had great challenges getting the old pulley off. Since it had a chip in it I bought a new pulley which does match up to the original. Problem is even with the tool I can't get the pulley to mount straight onto the shaft. As soon as I start getting pressure on the nut the pulley gets crooked. I'm afraid to try to force it since it is some sort of composite material. I did put some grease on the shaft without any change. Anyone out there run into this issue before? The shaft from the pump is straight and I even tried the bolt and nut that came with the new pump in addition to the tool I rented from Autozone. The pulley has to go on after the pump is installed in the bracket. The only thing I can think of to try at this point is to soak the pulley in hot water for a few minutes and then try it again. Any suggestions or tips are most welcome, thanks in advance!

 

[nexis]

Had a similar problem when i was doing this with mine, i pulled it back off the engine, put it on the bench, set the pulley on the shaft, put a block of wood on top, then smacked it with a hammer. Got it seated down far enough so i could put it the rest of the way on with my remover/installer.

 

[BrooklynBay]

Welcome to this forum! That method of tapping it is probably the best way to start it. Don't hit the plastic sides. Make sure that you tap it on the center. A rubber mallet would work fine.

 

[BrooklynBay]

Take a look at this set: http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=40749

You get a pulley remover, installer, and a plastic carry case for $10!

 

[ricco750]

Take a look at this set: http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=40749

You get a pulley remover, installer, and a plastic carry case for $10!

Bingo! I had the same problem getting my new pulley on using the rented tool from Autozone, and suspected the tool was worn. Bought this set that BrooklynBay recommends, pulley went on no problem.

 

[9blackex1]

did you all (with exception of Nexis) install the pulley with the pump on the engine, or did you have to remove the pump in order to do this.