Can Not Find Power Steering Pulley for My 2006 with 5/8" Bore

[FPollard]

I've got a fun one I can't find any answers for yet, I have a 2006 with about 130K on the clock. About a week and a half ago, something kicked up on a forest service road, bent my power steering pulley and took out the seal. It started out that everyone was selling me the wrong seal kit, so I bought a reman pump (the one without the bolt on back and the smaller shaft). Now I can not locate a pulley that is the correct diameter (6 1/8") with a 5/8" bore for the shaft. Everywhere online and off, they cross reference a pulley that is the correct diameter, but has a 11/16" bore which is too big for the shaft. I need to get my truck back on the road, so a solution would be greatly appreciated!

 

[mfurrh55]

I've got a fun one I can't find any answers for yet, I have a 2006 with about 130K on the clock. About a week and a half ago, something kicked up on a forest service road, bent my power steering pulley and took out the seal. It started out that everyone was selling me the wrong seal kit, so I bought a reman pump (the one without the bolt on back and the smaller shaft). Now I can not locate a pulley that is the correct diameter (6 1/8") with a 5/8" bore for the shaft. Everywhere online and off, they cross reference a pulley that is the correct diameter, but has a 11/16" bore which is too big for the shaft. I need to get my truck back on the road, so a solution would be greatly appreciated!

 

[mfurrh55]

Check this out...

 

[FPollard]

Check this out... View attachment 115002 View attachment 115001

It says in the right in the description that the bore on the pulley you posted a link to is .663" which is 11/16", not .625" or 5/8" which is far to large to achieve the required friction fit (it will spin freely on the shaft, without turning it at all). I've been trying to locate this part for a week and I really have not only looked everywhere I can think of, but have purchased at least 3 pulley's not listed for the vehicle that various "experts" have sworn will work... None to date have and the cross references online as well as at the 3 national chains who have ordered the part for me are incorrect. I even went as far as to purchase a remanufactured replacement power steering pump, which my bent factory pulley pressed on to perfectly, but none of the aftermarket pulleys will fit it.

 

[cerberusiam]

You are probably going to have to upgrade the pump to the latest revision along with the replacing the pulley.

 

[FPollard]

Thanks for searching for me, but that is 1/16" too large at the bore. See my reply to the Amazon link you posted...

 

[FPollard]

You are probably going to have to upgrade the pump to the latest revision along with the replacing the pulley.

I did that today, but was hoping someone had another solution. I've read several posts on other forums that hinted at a Ford part that had the same diameter and the 5/8" bore, but I can't find any tangible evidence of this pulley... For those who don't know, a damaged ps pulley on a Gen 3 apparently requires purchasing a new pump (the 2007.5 Gen 4 version), reservoir and reservoir mounting bracket along with a new pulley that has a 1/32" <corrected> larger bore to fit the shaft on the newer gen pump, just to replace a damaged power steering pulley on a Gen 3 truck... This is fairly expensive compared to the Gen 3 power steering pulley (over $300 versus about $30), when considering the Gen 3 pump is still readily available on the market...

 

[mfurrh55]

It says in the right in the description that the bore on the pulley you posted a link to is .663" which is 11/16", not .625" or 5/8" which is far to large to achieve the required friction fit (it will spin freely on the shaft, without turning it at all). I've been trying to locate this part for a week and I really have not only looked everywhere I can think of, but have purchased at least 3 pulley's not listed for the vehicle that various "experts" have sworn will work... None to date have and the cross references online as well as at the 3 national chains who have ordered the part for me are incorrect. I even went as far as to purchase a remanufactured replacement power steering pump, which my bent factory pulley pressed on to perfectly, but none of the aftermarket pulleys will fit it.

.6875 equals 11/16"

 

[mfurrh55]

5/8" is 0.6250

 

[FPollard]

.6875 equals 11/16"

You are correct, a .663 bore is actually 21/32", but it is still way too large for a friction fit on a 5/8" shaft. I have been rounding to the nearest 16th for the past week when describing the problem to the online and offline store parts clerks, few of whom seemed to grasp the problem with the subtle difference in size...

 

[mfurrh55]

Well good luck...thought I'd see if I could help, Monte

 

[mfurrh55]

• If you find one let me know, I have a 3rd gen too

 

[FPollard]

5/8" is 0.6250

As for your .6250 response: a fraction, when shown as a decimal, the accepted practice in mathematics is to drop the trailing "0" since in has no impact on the number you are trying to relate and is unused in calculations...

 

[FPollard]

• If you find one let me know, I have a 3rd gen too

Will do... For sh!ts and grins, I tried a slightly smaller diameter Ford pulley (5.86" I believe) with the correct bore size, but it obviously spins the pump shaft faster and at full lock on the wheel, the fluid getting pushed through the cooler couldn't keep up so the pulley heated, swelled and spun off the shaft. One of the national chain parts clerks tried to tell me that, "the pump will work better with a smaller pulley". I had asked for it and decided to try it only because there is a very limited selection of parts in Flagstaff, AZ and I am getting tired of being without my truck... Thankfully, it spun off about 10 seconds after starting my truck as I was backing out of my drive.

 

[FPollard]

Well good luck...thought I'd see if I could help, Monte

Monte, I meant it when I said I appreciated your search, you gave me hope for a minute. It has been a very frustrating 7 days for me, first trying to identify why I was encountering these problems, then trying to find a solution... There is very little online covering this topic and the repeated direct cross references to parts with the wrong bore size made it terribly difficult to explain...

 

[mfurrh55]

As for your .6250 response: a fraction, when shown as a decimal, the accepted practice in mathematics is to drop the trailing "0" since in has no impact on the number you are trying to relate and is unused in calculations...

I was just copying off the chart

 

[ranger 393]

I ran into the same problem, I ended up buying the whole unit from here.. https://www.alldodgetruck.com/

 

[FPollard]

I ran into the same problem, I ended up buying the whole unit from here.. https://www.alldodgetruck.com/

Thanks for the lead, but they don't seem to have any in stock today and I need to get my truck back on the road... Hopefully your link will help someone else reading this post in the future and I have bookmarked the link for my future parts needs.....

 

[FPollard]

I was just copying off the chart

I know and I apologize for the sharp retort, I'm just frustrated that I wasted a week trying to find a replacement pulley...

 

[Superdawg]

FPollard,
I located the pulley your are looking for in my pile of Dodge steering parts.....
The catch: I marked it bent? some years ago. It may be fine, it could have been the shaft on the steering pump
Part 53034166AA
The inner bore mikes out at .632
I would be happy to ship it out to you, just PM me your address.
Tom