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I’m not a machinist, please excuse my language.
What should shaft diameter of power steering pump be with respect to pulley inside diameter?
Is there a specific tolerance that is customary?
This happens to be steel-steel combo.
What if pulley was aluminum and shaft steel?
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My wag is it probably depends on the size of the shaft, but maybe a couple thou.
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Typically a press fit of that type would be in the 0.003" range.
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Last year, I had a pump seize up on me.
The belt smoked on stopped pulley and pump.
Removed failed pump and reused pulley on rebuilt pump.
I used my p/s pulley puller and it was still a tight fit.
Less than 5 miles down the road and not driving like an idiot either, something didn’t sound right under the hood. Was driving at 55 mph and less.
Pulled over ASAP and popped the hood.
The pulley and now two part serpentine belt was laying at bottom of engine compartment.
I looked at bright side, radiator was still intact.
Late for my burger joint date with some friends, I threw on my short belt and had a great dinner.
The short belt bypasses p/s pump...FYI.
Didn’t have time (snow relocation program) or inclination to look at it in below freezing non heated garage this winter.
It should be above freezing this week.
Inside of pulley is scored a little and pump shaft has a slight burr in a spot.
The pump shaft appears to measure consistently at different heights and at different position around the shaft with calipers.
Just don’t want this to occur at highway speeds.
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In manufacturing, Interference fits rely on a complicated equations which takes into consideration many factors. A few are, amount of torque that is applied to the joint, depth of fit, material dissimilarity, etc. There are more criteria, all engineering jargon
The engineering formula is too complicated to discuss here besides I hardly ever used it at my job.
The simple guide lines I always used which rarely got me in trouble was for diameters 1” or less are; .001”- .002” with .0015” being the median.
As the shaft diameters increase the hole size gets smaller, eg 4” shaft .004” .
If you want to be safe use a shrink fit, go on the high side maybe .002” - .0025” interference and heat the pulley, cool the shaft.
As for aluminum pulley’s go for the tighter fit with a shrink fit.
I would use a micrometer to check the shaft size on the pump and a telescopic hole gauge on the pulley that fell off to see what the issue was in the first place. Could have been a QC problem, shaft size minimum, bore size maximum.
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I would wonder where the pumps are coming from? Is the pulley spinning on the pump or is the pump seizing?
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Pump seizing or not the belt should be screaming and jump off before the pulley spins.
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Rudi wrote:
Pump seizing or not the belt should be screaming and jump off before the pulley spins.
My thoughts exactly.
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Did a little further investigation on this today.
The pulley hub has a 1” depth.
I used a sharpie and colored the shaft of the pump.
I was able to push the pulley onto the shaft over 1/2” in its normally mounted direction.
I then flipped the pulley 180 degrees front to back, I could only get the pulley to line up on the taper.
Pulley hub is definitely shot on rear half.
Found a replacement from TimC today.
Looking at the hub how it is attached, looks like its pressed in and staked.
Pulley appears to still be true, just hub is damaged.
Can the hub be removed and replaced?
Now if I had Rudi’s skills I’d fix it in my sleep.😁
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I've never seen a hub replaced in a pulley. Not saying it can't be done, but without knowing for sure how it was put together it seems like the end result may be that the pulley winds up out of kilter to the hub and just compounds the problems. A lot of times these things are assembled at the factory by having the pulley red hot and the hub cold, putting them together in a fixture and letting it cool. That's not really a press fit; its a shrink fit. Trying to press it apart typically damages something to where it never goes back together right again. I would just get a new pulley and be done with it.
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Dan , if you have access to a lathe there is no problem pressing in a new hub. The new hub should be at least welded in place and the pulley chucked in a lathe, TIR verified, the the hub bore machined to the press fit diameter.
OR . . . bore the existing hub out to the next nominal size press in a bushing and bore it out in a lathe, many ways to skin a cat.
That’s the best way to ensure everything is concentric.
It all boils down to the time line to fix it or money to get a new one.
If you lived closer and not in another country I’d fix you right up for ya.
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I would make the new bushing an interference fit and to be safe should be welded , it stays with the pulley when removed.
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Thanks Rudi for the lesson.
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This past week I installed the pulley on my PS pump. In the past when I installed these pulleys I used some oil on the shaft and always had a tough time with the pulley turning during installation. After reviewing a YouTube video that recommended using a EP grease on the shaft, tired t and found the pulley went on smoothly without any difficulties.
Note that the old and new pump shafts had the same diameter.
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