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How I Removed a Power Steering Pulley from a Volvo 240 200 1991

posted by  joe_1991_240 on  Tue Dec 30 19:58 CST 2014
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How I Removed a Power Steering Pulley from a Volvo 240:

If you try to remove a pulley from a power steering pump with a generic rental tool kit you may encounter a problem - it may not be tight enough to grip the pulley firmly and successfully remove it from the power steering pump shaft. It may slip off the central pulley lip, or bend the lip, because of the loose grip.

After an unsuccessful search for a Volvo tool for the job, and after visiting a local automotive shop that attempted and failed to remove it, I decided to modify a standard pulley removal kit to more tightly grip the Volvo pulley. I purchased the pulley removal kit from a discount store for about $17, then used an angle grinder to modify it. The pulley was then successfully removed within minutes.

The image below shows how I modified the kit. The goal is to grind the parts so that you have the tightest grip possible on the central pulley lip.







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