Repaired old power steering pump

[ibrw1]

I removed pump from engine, I removed pulley with approved puller remover/installer kit. I removed reservoir I got part number off the old casting on the pump. Bought new pump using those numbers. I matched the numbers on the new pump. I exchanged regulator, replaced the reservoir. Everything looks perfect. I try to reinstall pulley. Won’t go. Neighbor is GM freak, drag races everywhere. I hand him my pump, my kit and my old pulley. Pump shaft is bigger than the pulley inside diameter. Pump with EXACT SAME PART NUMBER as the old one has a larger shaft. My company has a massive CNC marching shop. I’m going to have one of the machinists cut the proper ID into the pulley. I bought a new pulley AMAZON. is too small as well. Not looking for help, looking for the story as to how this happened. Went to buddies house. His pump shaft is .75” just like my new pump.

 

[Bondo]

Ayuh,..... 1st I've heard such a thing,..... What's the other diameter ya found,..??

Wonder whether it might have to do with convertin' manufacturin' tools to metric production,..??

 

[ibrw1]

New pump shaft outside diameter is .75 inches
old pulley is ABOUT .746 I bought another pulley. It won’t fit either. I won’t have exact size of IDs till I get to work. I called buddy with 6 banger his boat measured at .75

 

[ibrw1]

So, went to work with new pump and new pulley. Showed it the a mechanical engineer and 2 machinists. They measure shaft at EXACTLY .7495 They measure pulley ID at .743 EXACTLY. Everyone says ain’t no freaking way your going to get this pulley on that shaft. I previously proved that. We cut the ID AT MY REQUEST to ID = OD. I grabbed my semi-high dollar puller put-er-on-er in place. Cracnked my nuts off. Got it on. Mind you I used never seize. It ain’t coming off either. Pump is 7830247. Same exact numbers as old pump. The pulley is same one sold everywhere. $50.00 on eBay.

 

[ibrw1]

Everything is fixed. Just for matter of record the part number for the pump pulley 861578. I actually got the pulley on Amazon. I use ebay as reference because their search is better. Amazon is usually more money but worth it if something goes wrong.