Broken Power Steering Pulley

[burtonrider11]

This past weekend, I fell victim to the dreaded plastic pulley breakage on our 97 5.7. We were cruising at around 2900 rpms, when my wife said she "heard something" and the steering all of a sudden got tougher to turn. I cut power and shut her down within 10-15 seconds of this all occuring. I opened up the hatch and all that was left of the pulley was what you see in the photo.

I don't believe any other damage occurred, the temp gauge never much higher than normal, certainly not into overheat range. I didn't smell any burning rubber smell. To me it looks like Merc issued a recall on these pulleys but that has long since expired. So I understand that the 4.75" plastic is to be replaced with a 5.75" metal pulley and new serpentine belt. The current pump seems to spin freely and the belt looks fine overall, so I don't suspect any other accessories had seized that caused this.....A little disappointing that our day was cut short over a stupid plastic pulley

I can pull apart my boat to get access to the front of the pump, however, I am wondering if it would just be easier to remove the pump and do all the work out of the boat? I do understand that I need a pulley puller. What about putting it back on? A vice or press?

Or another thought, since the pump is well near 20 years old, should I find an OEM retrofit and replace the entire pump and pulley?

My only concern with unhooking the pump is bleeding/introducing air into the lines. I know how to bleed brakes but not a power steering system.

I would appreciate any input or any advice anyone has on this!

http://i1053.photobucket.com/albums/s471/burtonrider11/IMG_3833_zpsvqo1iww7.jpg

 

[Bt Doctur]

just refill and run it, it will self bleed, a few cycles of full left and right.I would just replace the pully without removing it.

 

[Scott Danforth]

just replace the pulley, top of the fluid, spin the wheel lock to lock a few times to bleed and go boating.

 

[KD4UPL]

I had the exact same thing happen to me. I found a replacement pulley and belt at a marina. I went to a local Advance Auto and got a GM power steering pulley removal and installation tool. I replaced the pulley and we were back on the water. I think the whole episode only took about 2 or 3 hours. I don't see why you would need to remove the pump unless your engine access is that tight. I found it helpful to have the pump still on the engine. It held it still and when I put the belt on it held the pulley still while I tightened it back on the shaft.

 

[GA_Boater]

If it's as tight a fit as the photo shows, it might be best to take the pump off.

 

[gm280]

I would either remove the pump OR drill a huge hole in from the front so you could install a new pulley. but that hole is going to be huge. :facepalm:

 

[burtonrider11]

Thanks for all the help and advice guys! As it sits, yes it would be a tight fit, much too tight to be able to do the work needed. What you are looking at is the back of our bench seat. It really isn't a huge issue to remove it to work on the pump. However it's held together with brackets and a bunch of stainless screws - a lot of them!

So I can either remove the bench seat or remove the pump. I am kind of thinking keeping the pump in place is a better idea. I am not a huge fan of pulling off hoses if I don't have to....It should also help with keeping the correct tension on the belt when it gets re-installed.

Is there any reason I HAVE to use the Merc replacement kit? It looks like it would be $100, but could I just find a same size belt and pulley and use that? I believe the belt is 2197mm and I found a 2195mm 6 rib belt by Dayco and am sure I could find similar belts at auto parts stores. I like the idea of buying a belt with a 3 year warranty if possible. If I can pull what's left of the pulley that's still on the shaft, I could match up the key and size of the old one to a new one.

Also, and this is just me being anal, but do I have to go to bigger pulley? Isn't a bigger pulley going to draw slightly more HP? Maybe on that pump it doesn't matter. Most likely I am WAY overthinking things here

 

[achris]

If you can find a replacement that is the same, go ahead and use that. Mercs' over-inflated 'marine tax' is enough to drive anyone to aftermarket. You'd be surprised what I've found on my Mercruiser that I can source elsewhere.

Bigger pulley will draw LESS power. It's spinning the pump slower.

Chris....

 

[burtonrider11]

If you can find a replacement that is the same, go ahead and use that. Mercs' over-inflated 'marine tax' is enough to drive anyone to aftermarket. You'd be surprised what I've found on my Mercruiser that I can source elsewhere.

Bigger pulley will draw LESS power. It's spinning the pump slower.

Chris....

Thanks Chris. I just ordered belt that is a 2195mm versus the 2197mm I am assuming that the tensioner adjustment will allow for this belt to fit. I think the only challenge is going to be finding the pulley. I think I found an automotive one for $30. It's a 5.75" pulley. The only concern is whether it will fit the spindle.

Worst case scenario, I can't find a pulley so I buy the Merc kit, keep the belt I already bought and I have a spare belt to keep on board

I'll keep everyone posted on how it goes and if my "kit" works for me, I'll post the specs so others can do the same....

 

[harleyman1975]

You realize a larger pulley may require a larger belt?

 

[NHGuy]

Yes, plus you could unbolt the pump from the bracket but leave the fluid lines attached. Then remove the old hub as needed reinstall the new pulley, reinstall the pump to the bracket and install the belt.

 

[burtonrider11]

You realize a larger pulley may require a larger belt?

Yes, the 2195mm belt is the larger belt to accommodate the larger pulley

 

[harleyman1975]

Cool!

 

[burtonrider11]

Just a quick update: I ordered the Sierra part 18-8297 which is a direct fit replacement for Merc part number 57-861758. This is the 5.75" pulley. I was able to order right here off iboats for $52 including shipping. This brings my total to $65. To order the kit that includes belt and pulley, the cheapest I could find it was $88. I'll post specs of the pulley as well. There may well be a cheaper non marine version, however, I didn't want to chance it and spend more time chasing parts. At least if the specs are out there (I couldn't find any) people can use them to match them up to replacement parts in the future. Should hopefully have everything here by this weekend, I'll post updates then. Thanks again for all the help!