Tools You'll Likely Need:
* Pulley puller: A suitable three-jaw or other type of pulley puller specifically designed for this application. The size and type will depend on the pulley. A generic puller might not work.
* Wrench(es): Appropriate size(s) to remove the pulley bolt(s) (likely a large socket). A breaker bar may be necessary.
* Socket wrench set: For various nuts and bolts you might encounter.
* Penetrating oil (like PB Blaster): To help loosen any seized bolts or the pulley itself.
* Gloves: To protect your hands.
* Jack and jack stands (or ramps): To safely lift the vehicle.
* Wheel chocks: For added safety.
* Ratchet and extensions: To reach the pulley bolt comfortably.
Procedure:
1. Safety First: Disconnect the negative battery cable. Raise the vehicle and securely support it with jack stands. Engage the parking brake and use wheel chocks.
2. Access the Pulley: Locate the power steering pump pulley. You'll likely need to remove some belts or components to gain sufficient access. Refer to your repair manual for the specific belt routing and removal procedures.
3. Loosen the Pulley Bolt: Spray penetrating oil on the pulley bolt. Let it soak for a while to help break any corrosion. Use the appropriate wrench and breaker bar (if needed) to loosen the bolt. It will likely be very tight. Turn counter-clockwise.
4. Remove the Pulley Bolt: Once loosened, completely remove the pulley bolt.
5. Install the Pulley Puller: Carefully position the pulley puller according to the manufacturer's instructions. Ensure the jaws are evenly gripping the pulley without damaging it.
6. Remove the Pulley: Slowly and steadily tighten the puller's center bolt. This should draw the pulley off the shaft. If it's very stubborn, apply more penetrating oil and try again. Avoid using excessive force, as you could damage the shaft or pulley.
7. Clean and Inspect: Once removed, clean the pulley and shaft. Inspect for any damage.
8. Reassembly (in reverse order): After completing your repairs, install the new pulley (if necessary) and reinstall the pulley bolt, tightening it to the correct torque specification as specified in your repair manual. Reinstall the belts and other components you removed.
9. Lower the Vehicle: Carefully lower the vehicle. Reconnect the battery cable.
Important Considerations:
* Seized Pulley: If the pulley is extremely seized, you might need to use heat (carefully!) to help loosen it. Never apply heat directly to the power steering pump itself.
* Damaged Pulley or Shaft: If the pulley or shaft is damaged during removal, replace them immediately to prevent further problems.
* Repair Manual: This is crucial. Every vehicle is slightly different, and a manual will give you the specific details for your Aerostar. Improper procedures can damage your vehicle.
This is a general guide. If you're not comfortable performing this repair, take your Aerostar to a qualified mechanic. Working on power steering components can be dangerous if not done correctly.
