Tools You'll Likely Need:
* Power steering pulley puller: This is crucial. A standard three-jaw puller might work, but a specific power steering pulley puller designed for the 3.8L's setup is preferable.
* Socket wrench (likely 15mm or 17mm): To remove the power steering pump mounting bolts (if necessary for access).
* Wrench (appropriate size): To hold the power steering pump shaft stationary.
* Ratchet and sockets: For various fasteners.
* Penetrating oil (like PB Blaster): To help loosen any stubborn bolts.
* Torque wrench: For proper tightening upon reassembly.
* Gloves and safety glasses: To protect yourself.
Procedure:
1. Safety First: Disconnect the negative battery terminal. This prevents accidental short circuits.
2. Access: You'll need to access the power steering pump and pulley. This might require removing other components depending on your access – possibly the serpentine belt, and potentially some other components near the power steering pump. A repair manual will show you the best approach for your car.
3. Remove the Serpentine Belt: If necessary, remove the serpentine belt to access the pulley. Consult your repair manual for the correct routing and procedure.
4. Prepare the Pulley Puller: Position the power steering pulley puller according to its instructions. It will likely have some sort of center bolt that engages the pulley, and arms that contact the power steering pump.
5. Secure the Power Steering Pump: You MUST prevent the power steering pump shaft from turning while you are removing the pulley. Use a wrench to hold the shaft stationary. Otherwise, you risk damaging the pump.
6. Tighten the Pulley Puller: Carefully tighten the center bolt of the puller. This will pull the pulley off the shaft. Apply steady pressure – don't use excessive force or you risk damaging the pump or the pulley.
7. Remove the Pulley: Once the pulley is loose enough, remove it from the shaft by hand.
8. Clean Up: Clean the power steering pump shaft before reinstalling the pulley (if you are replacing it).
9. Reinstallation (Reverse Order): Reinstall the pulley and the serpentine belt (if removed) in the reverse order of removal. Use the torque wrench to tighten all bolts to the manufacturer's specifications (found in your repair manual).
10. Reconnect the Battery: Reconnect the negative battery terminal.
Important Considerations:
* Seized Pulley: If the pulley is seized, penetrating oil might be needed. Apply it and let it soak for a while before attempting to remove it. A heat gun (used carefully and cautiously to avoid damage) can also help loosen a stubborn pulley.
* Damaged Pulley/Pump: If the pulley is severely damaged or the power steering pump is showing signs of wear, consider replacing them. It's not worth risking further damage by trying to force a damaged part.
* Professional Help: If you're uncomfortable performing this task, take your vehicle to a qualified mechanic. This is not a beginner-level repair.
Remember: This is a general guide. Always refer to a repair manual specific to your 1990 Ford Thunderbird 3.8L for the most accurate and safest procedures. Failure to follow proper procedures can lead to injury or damage to your vehicle.
