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How-to

1986 Ford Bronco Remanufactured Saginaw Pump and Fluid Flush

1986 Ford Bronco · Swap · Moderate

Documented by SuperMotors from Sixlitre’s photos

A worn Saginaw power steering pump on a 1986 Ford Bronco is diagnosed by shaft play and replaced with a remanufactured Cardone unit. The pulley and mounting bracket are transferred to the new pump on the bench, new low pressure hose is fitted, and the system is flushed with a clear hose and drain pan.

  1. Step 1

    Grab the power steering pump pulley and check for in and out movement on the shaft. Sixlitre chased a belt squeal for about 6 months until it turned into metal on metal bearing noise, then found the Saginaw pulley moved in and out a good 3/16", and sourced a cheap remanufactured Cardone Saginaw listed for a 78 Ford Econoline van as the replacement.

    Even the best breaks eventually. I'd been trying to trace the belt squeal for about 6 months. Eventually it started to sound like metal on… (1986 Ford Bronco) Got another remanufactured Cardone Saginaw for "my 78 Ford Econoline van" for cheap enough to replace the whipped unit. (1986 Ford Bronco)

  2. Step 2

    Undo the hose clamp on the low pressure return line. Slack off the half inch cooler pipe retaining clamp bolt to make the hoses easier to pull off and refit, and remember to re-tighten it later.

    Started by undoing the low pressure return line's hose clamp, visible on hose. (1986 Ford Bronco) Slacking off this half inch cooler pipe retaining clamp bolt helps get the hoses off and on. Just remember to re-tighten it later. (1986 Ford Bronco)

  3. Step 3

    Attach a clear hose to the cooler and drape the free end into a drain pan so the old fluid can be flushed out. Sixlitre flushed the fluid even though it looked clean, expecting filings somewhere in the system.

    I wanted to flush my old fluid out, even though it was clean to look at I'm sure there were filings in there some where. To do this I just… (1986 Ford Bronco)

  4. Step 4

    Crack the high pressure hose fitting loose before any mounting bolts are slackened, while the pump is still held steady. Then loosen and remove the two mounting bolts, take the belt off and lift the pump out. It leaks and spills fluid as it comes out.

    Next, before you slack any mounting bolts, crack loose the high pressure hose fitting. It's easier now than when the pump is loose and hard… (1986 Ford Bronco) Then just loosen off and whip out the two mounting bolts. (1986 Ford Bronco) Off comes the belt and out comes the pump, leaking and spilling all over the place. (1986 Ford Bronco)

  5. Step 5

    Clamp the pump in a vise to work on it. Put a little penetrating oil on the shaft to help the pulley come off.

    Clamped her into the vice so it's easier to work on. (1986 Ford Bronco) A little of your favourite penetrating oil onto the shaft will help the pulley come off more easily. (1986 Ford Bronco)

  6. Step 6

    Use a power steering pulley puller tool kit to pull the pulley without damaging the pump. Sixlitre borrowed the kit from a local jobber and turned it with a two foot flex bar rather than a ratchet.

    Borrowed a PS pulley puller tool kit from a local jobber to re and re the pulley without damaging the new pump. (1986 Ford Bronco) Why use a ractchet when a two foot flex bar can do the job so much more easily, and they wonder how these loaner tools get broken !? Use li… (1986 Ford Bronco)

  7. Step 7

    Undo the bolts and stud holding the bracket and transfer the bracket onto the remanufactured Saginaw. Sixlitre's pump carried one stud on the back that holds the 78 van bracket on with a nut.

    Now just undo the bolts and stud and transfer the bracket onto the remanufactured Saginaw. (1986 Ford Bronco) Mine had one stud on the back of the pump to hold the 78 van bracket on with a nut. (1986 Ford Bronco)

  8. Step 8

    Put a little synthetic grease on the new pump shaft so the pulley slides on. Press the pulley on with the same puller kit, tightening only until it contacts the shaft snout, and stop at that point.

    A little synthetic grease onto the shaft to help the pulley slide/pull on. (1986 Ford Bronco) The pulley puller also installs the pulley onto the new pump shaft very well, by tightening it up until it contacts the shaft snout (stop a… (1986 Ford Bronco)

  9. Step 9

    Fit the new low pressure hose while the pump is still on the bench and easy to reach. Sixlitre used two opposed hose clamps on the joint to ensure no leaks.

    I choose to put the new low pressure hose on now, while it's on the bench and easy to tighten the two opposed hose clamps I'm using to ensu… (1986 Ford Bronco)

  10. Step 10

    With the clear hose already running from the low pressure return pipe of the cooler into the drain pan, push a drill bit into the new low pressure hose on the pump to block it. The bit pulls back out easily once enough fluid has been cycled through to flush the system.

    To flush the pump I've already added that clear hose to the low pressure return pipe of the cooler and dumped it in the drain pan. Now I sh… (1986 Ford Bronco)

  11. Step 11

    Bolt the new pump up in place and fill it with fluid ready to flush through. Sixlitre had been running the synthetic fluid and switched back to the thicker regular fluid, expecting that to cure a very slow, almost non-leak.

    I had been using the synthetic stuff on the right, but I'm going to flush it out and use the regular thicker stuff. I'd developed a very sl… (1986 Ford Bronco) There's my new canned ham all bolted up in place and filled up with fluid ready to flush through. (1986 Ford Bronco)

  12. Step 12

    Once the flushing is done, remove the clear hose and fit the new hose onto the cooler pipe with two opposed hose clamps. The photos end here.

    Now that the flushing is done I removed the clear hose and installed the new PS hose with two opposed hose clamps as seen here. (1986 Ford Bronco)

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