Safety First:
* Disconnect the negative battery cable before beginning any work.
* Wear safety glasses and gloves.
* Support the vehicle securely on jack stands. Never work under a vehicle supported only by a jack.
* Have a drain pan ready to catch fluid. Power steering fluid is messy and harmful to the environment.
Tools You'll Likely Need:
* Socket wrench set (metric)
* Wrenches (metric)
* Power steering fluid (use the correct type specified in your owner's manual)
* Drain pan
* Funnel
* Rags or shop towels
* Torque wrench
* Possibly a pry bar or a puller (depending on how stubborn the pump is)
Steps:
1. Locate the Power Steering Pump: The pump is usually located on the engine, typically driven by a belt. Consult your repair manual for its precise location on your specific engine.
2. Drain the Power Steering Fluid: Locate the power steering fluid reservoir. Remove the cap and carefully drain the fluid into your drain pan.
3. Remove the Drive Belt: Use a belt wrench or appropriate tool to loosen and remove the serpentine belt. You may need to consult a diagram to understand the belt routing. Remember which way the belt goes around the pulleys.
4. Disconnect the Power Steering Lines: There are typically two lines connected to the power steering pump: a pressure line (usually thicker) and a return line (usually thinner). Use wrenches to carefully loosen and remove the connections. Have rags ready to catch any spilled fluid. Be prepared for some fluid to leak out.
5. Remove the Pump Mounting Bolts: Locate the bolts that hold the power steering pump to the engine. Use a socket wrench to remove these bolts.
6. Remove the Power Steering Pump: Once the bolts are removed, the pump should come off. It might be stubborn due to corrosion; you may need to use a pry bar (gently) or a puller to help remove it.
7. Install the New Power Steering Pump: Carefully install the new power steering pump, ensuring it's seated correctly. Tighten the mounting bolts to the manufacturer's specified torque (consult your repair manual).
8. Reconnect the Power Steering Lines: Reconnect the power steering lines, making sure they are securely fastened. Again, use a wrench, not just your hands.
9. Reinstall the Drive Belt: Carefully reinstall the serpentine belt, ensuring it's correctly routed around all the pulleys.
10. Add Power Steering Fluid: Remove the reservoir cap and add the correct type and amount of power steering fluid, as specified in your owner's manual.
11. Bleed the System (Important): This step is crucial to remove any air trapped in the system. Start the engine and turn the steering wheel fully lock-to-lock several times while monitoring the fluid level in the reservoir. Add more fluid if necessary. Consult your repair manual for specific bleeding procedures.
12. Check for Leaks: Inspect all connections for leaks.
13. Reconnect the Battery Cable: Reconnect the negative battery cable.
Important Considerations:
* Repair Manual: A factory service manual for your specific 1996 Plymouth Voyager is highly recommended. It will provide detailed diagrams, torque specifications, and step-by-step instructions.
* Professional Help: If you're not comfortable performing this repair, it's best to take your vehicle to a qualified mechanic. Improper installation can lead to damage to your power steering system or even engine damage.
* Fluid Type: Use the correct type of power steering fluid. Using the wrong fluid can damage the pump and other components.
This is a general guide. Always refer to your vehicle's repair manual for detailed and accurate instructions specific to your 1996 Plymouth Voyager. Remember safety first!
