For a while my power steering pump
intermittently made whining noises. Not unbearable, but I knew it
would get worse. Finally it started to get worse and worse, up until
the point that It sounded like whales humping under my hood! I looked
around for replacement pumps, and found the cheapest was Napa $150 (+ 50
refundable core charge). They had to order it in for me, took a day or
2. It did not include the reservoir, but I just simply re-used the old
one. I'll tell you how I went about swapping out the old for new.
(like new, its remanned.)
First thing to do is remove the air box from the engine compartment.
There are 3, or 4, 12mm bolts that hold the box in and 2, 10mm bolts that hold
the MAF to the air box.
Next step is to disconnect the return line and pressure line. But
before you do this, you need to get an oil drain pan under the rig.
Also remove the skid plate so the oil can drain right into your oil pan.
(I'm an idiot and didn't do that, and all the fluid ran onto the skid plate
and then hit the drain pan.) The return line is a small rubber hose
that connects directly to the reservoir and hangs down. Squeeze the
clamp and pull the hose off. BUT...be careful. A lot of fluid
will drain out when you take this hose off. All of what is in the
reservoir will come out. Plug the hose up so that no contaminates get
in the line. Next remove the pressure line, which is a large
17mm bolt. You will also need 15/16" wrench to hold the fixed nut
attached to the power steering pump. As you loosen the bolt, fluid
will pour out. Make sure you get it in the pan. Remove the odd
looking bolt with holes in the middle. Also make sure you don't loose
the little washer thing attached to the pressure line fitting. Plug
the pressure hose so no contaminates get into it. Here's what it will look
like:

Next you need to remove the pulley. It is held on by 1 bolt, 17mm.
Remove the nut. Then the pulley will slide right off. Then take
the belt off. You will need to jam something in the pulley to keep it
from moving on the shaft. I tried a few things, but a wrench jammed in
between the pump, through the pulley, and into the fan shroud worked the
best. Here's what it looked like:

Next thing to do is remove the 3, 14mm bolts holding the pump on to the
motor. There is one, long bolt that holds the pump onto the motor, and
2 shorter bolts that hold it onto the adjusting bracket. Now the pump
will come off the rig. Be careful as you take it out because there
will be fluid still in the reservoir, and you don't want any fluid on your
paint. Here's what the old pump looks like, with the reservoir still
attached:

Now you need to take the reservoir off the old pump. There are 3,
12mm bolts to remove. After those are off, you may need to pry the
reservoir off of the pump with a screwdriver. Mine was pretty muddy
and dirty, but it came off with a few taps. When doing this, you will
leak some fluid, so do it somewhere where you won't make a mess.
Here's the old reservoir removed:

Next you need to put the old reservoir on the new pump. Just bolt
the 3 bolts back up to the new pump. Now the new pump is ready to be
bolted back on the truck. Here's what the new pump with and without
old reservoir looks like:


Slide the old pump back back onto the mounting holes, and hand tighten
the bolts. Now you will have to loosen a different bolt that you
didn't mess with when taking it off. This is the belt tension
adjuster. It is a small, 12mm bolt in which one of the shorter power
steering pump bracket bolts are connected. It is right under the
pressure line that you removed before. Its in a really tight spot.
But you can loosen it up by hand. You need to loosen that really good in
order to put the pulley back on.
Next you need to put the pulley back on, along with the belt. Make
sure you put it back the way it came on. It is very important that you
loosened the tension bolt I mentioned before. Slide the pulley back on
on the splined shaft. Tighten the bolt. Remember to jam a wrench
in the pulley again.
Now you need to put tension back on the belt. You do that by
tightening the tension bolt I mentioned before. This is the fun part.
With the pump and pulley bolted on, there is VERY LITTLE ROOM. I am
glad I have small hands. Even with small hands I have some good
bruises up and down my arms. Takes a while to get that bolt tightened.
Make sure you have sufficient tension on the belt, and then tighten the 3
bolts you finger tightened before.
After you have everything bolted up and ready to go, you need to refill
the reservoir and cycle the fluid through the pump. Fill the reservoir
up to the cold mark on the dipstick. Turn the truck on, and idle it
for a minute or 2. Then refill the pump if needed. Then turn the
wheels back and forth a few times. Check the fluid, and refill if
necessary. Then go for a test drive to make sure everything is
working. Your done! That's it!
There still is a very slight whine when I'm stopped and cranking the
wheel, but hardly noticeable. Nice and quiet now. It's great to
do this type of work yourself. I'm sure I saved a few hundred bucks.