Changing power steering pump on 2001 Chevrolet 2500HD with 8.1 engine with Hydroboost

1. Disconnect positive terminals from the Battery/Batteries

2. Remove tubing from intake to air filter box

3. Remove top part of fan shroud

4. Remove clutch fan using 1-7/16” wrench. (Having the correct wrench makes this job very easy. The fan uses standard right hand threads, so by placing the wrench on from the top, you smack the top of it with a hammer towards the passenger side. We use a Pro Grade brand combination wrench #11018, about $55 from Amazon)

5. Remove lower fan shroud, being careful of any transmission/coolant lines attached to it.

6. Remove serpentine belt

7. Remove both the plastic skid plate and the metal one a little further back if so equipped.

8. Remove high pressure line from rear of power steering pump using 5/8” flare wrench. Depending on the length of your wrench, this may be tricky, but I use the box end of another wrench in the opposing open end of the flare wrench for leverage.

9. There will be a bracket with two nuts on the back of the pump. The bracket is attached to the engine block by one bolt. Remove the bolt from the block. You may also remove the nuts from the back of the pump that attach it to the bracket. I didn’t have luck removing the bracket at this point due to space constraints. You need this bracket for your new power steering pump. Do not send it back with the core!

10. Remove two return lines. They are only held on by clamps.

11. Remove the power steering pump pulley.

12. Remove the four bolts from the front of the pump. They hold it to the bracket that runs up to the alternator.

13. At this point, you should be able to start wiggling the pump out. You may have to loosen the bolts on that bracket that also holds the alternator to give you a little more wiggle room to get the power steering pump out.

14. Remove the extension on the top of the pump. It looks like a short piece of rubber hose with a couple of clamps. It is where the dipstick for the pump is. You will need this part for your new pump. Do not send it back with the core!


To re-install, reverse the steps and flush, fill, and purge the system using new power steering fluid.
 

Note: Some people remove their pump without removing the clutch fan, but I appreciate having that little extra room as I have large hands and it’s not too hard to remove the fan if you have the proper wrench.

Note #2:  The top return line is for the hydro-boost. The bottom return line is for your power steering. If you choose to flush your system, the only way to get fluid to return from the top return hose is to step on the brakes while the engine is running. This will push fluid out of the top line. We catch it in an old milk jug when we flush so that we can see when clean fluid starts coming out. The bottom hose can be flushed by turning your wheel back and forth. Make sure to block the port on the pump that you have pulled the hose from as it will squirt fluid out of it as you flush.