Power steering pump replacement
When the going gets tough, the tough gets going...
I drive a 2003 TB EXT, which did not give me too much trouble until recently when the fan clutch decided to fail at the same time as the power steering pump (and I suspect the water pump too).
So, I took the matter in my own hands after getting some crazy quotes for the replacement of the above noted parts.
I shall describe the PSP replacement procedure, without removing the fan shroud or any other parts; unfortunatelly I did the work by myself and could not take pictures but I hope you will get the idea.
Step 1: Buy a new PSP (don't need the reservoir).
Step 2: Rent a PSP pulley removal\installation kit (kit #20 at Canadian Tire); there is no cost associated with this, as CT will refund your money upon return.
Step 3: Buy 2 liters of power steering fluid.
Step 4: Let the engine cool before doing any of the work described further.
Step 5: Remove the accesory belt (push down on the belt tensioner).
Step 6: Remove the air filter cover and filter to have some more room to work
Step 7: Remove electrical connector from the pump
Step 8: Using CT kit #20, remove the pulley; arm yourself with patience, as this will take a while due to the limited space (since you did not remove the front of the vehicle)
Step 9: Empty the reservoir (use a vacuum pump or a hose to suck the fluid from the reservoir to minimize spillage)
Step 10: Disconnect the hose clamp from the underside of the reservoir and pull down on the hose (wrap the hose in a cloth to reduce spillage)
Step 11: Unscrew the pressure hose from the underside of the pump body; again, wrap it with a cloth beforehand
Step 12: Unscrew the three bolts fastening the pump to the holding bracket; the pump can now be removed from the engine compartment
Step 13: Remove the two clamps which attach the reservoir to the pump; do not pry on the clamps. Use a flat head screwdriver to pull up on the lock and slide the clamps sideways, one at a time. Once the clamps are removed, the reservoir can be detached from the pump body
Step 14: Install the new gaskets which came with the new pump. Mounting of the pump in place is the reverse of the removal procedure
Once installation is complete, fill the reservoir with new fluid and start the engine. Check fluid level several times during the following procedure. With the engine running, turn the wheel both ways to work the pump and ge tthe fluid flowing. This will remove air from the system. Every week after the procedure (for the next couple of weeks), remove the fluid from the reservoir and replace with new fluid (remember that the fluid left in the hoses was not flushed).
In my case, the thing worked like new and I hope it will for you too.
Have fun, and don't blame it on me :-)