pressing on the power steering pump pulley (2002 XLT 4.6L)

[LMHmedchem]

I am most of the way through pressing the power steering pulley back onto the pump. I am using the same tool I used to remove it.

MADDOX Pulley Remover and Installer Set ($40)

The pulley was easy to remove with this tool, as was the pulley on the original pump.

I need to press the pulley on about another 2-3mm in order for it to be flush with the front of the shaft. Looking at the pulley, it doesn't quite line up with the other parts of the S-belt system. It's close, but I am afraid that the belt will walk off if I don't have this perfectly aligned.

The pulley want on just fine up to this point, though the directions seems to be incorrect.

The directions are (my version),

1. thread the jackscrew into the puller body
2. thread the Ford 4.6L Modular screw installer into the tip of the jackscrew and tighten
3. place the bearing and thrust washer over the screw installer
4. thread the screw installer into the end of the pump shaft and tighten all the way down

At this point, you rotate the puller body down the jackscrew threads until the washer is flush up against the pulley. All of this is fine. It is the next instruction that doesn't make sense.

5. hold the jackscrew with a 1/2" socket and turn the puller body counterclockwise with an adjustable wrench until the pulley is seated.

Turning the puller body counter clockwise (left/loose) just unthreads it up the jackscrew and away from the pulley. I don't see how this could possibly press the pulley onto the shaft. I did the opposite, I held the jackscrew with a 1/2" wrench and turned the puller body clockwise to run it further down the jackscrew threads. This pressed the pulley almost all the way on. Now, this same motion just seems to unscrew the screw installer from the pulley shaft, which I don't get because I am turning everything to the right.

What can I do to get the pulley the rest of the way on the shaft (other than a 5 pound hammer)?
Am I not using the tool correctly? If this is the case I guess I would appreciate an explanation of what I am missing.

LMHmedchem

 

[LMHmedchem]

I think that the problem is that as the pulley gets very tight on the shaft, the pulley starts turning clockwise. This unscrews the screw installer from the pulley. There is a bearing between the puller body and the pulley that I guess is supposed to prevent this. I may have had the bearing on backwards at first. Even with the bearing on correctly, the pulley still turns and backs out the screw installer instead of pressing on the pulley.

What I did was to place the handle of a small crescent wrench through the pulley so that it would bind on something and prevent the pulley from turning. I was careful to make sure that it wasn't pressing against anything that could be damaged. I didn't bother securing the end of the jack screw but just used a large crescent wrench to turn the puller body clockwise. This pressed the pulley further on with no issues. The pulley is not quite flush with the end of the shaft but it looks like if I push it on any further, it will be too far on and not in line with the next pulley. For now, I am going to leave it where it is.

I also manually turned the pulley while looking at it from the end to make sure it is on straight. There is no wobble that I can see.

I still don't understand the instructions for this tool. I don't see how they could possibly work.

LMHmedchem