I have a 99 voyager with 3.0 .do you have to remove the pulley first on the power steering pump befor you take out the pump.not much room to take out he pump with the pulley.thanks

hope this one help http://www.popularmechanics.com/cars/how-to/maintenance/3322636
This instructable is designed into four main parts. Here's the outline:

1) Gather the materials
-- Instructable step 1 - This includes tools, a new pump, fluids, etc.
2) Remove the leaking pump
-- Instructable step 2 - Drain the Power Steering system
-- Instructable step 3 - Remove accessories from Power Steering system
-- Instructable step 4 - Remove the pulley and bolts
-- Instructable step 5 - Remove power steering pump
3) Install the new pump
-- Instructable step 6 - Place the new power steering pump
-- Instructable step 7 - Press on the power steering pump pulley
-- Instructable step 8 - Align the pulley and attach the belts
-- Instructable step 9 - Flush and fill the power steering system
4) Cleanup
-- Instructable step 10 - Cleanup

You'll need some tools to complete this task. Before you start, gather the necessary equipment -- you will not be able to use the car once you start the replacement! It is always a good idea to have a friend on call, or a second car available.

Equipment list:

• Power Steering pump (to replace defective pump)
• Two (2) quarts power steering fluid or appropriate ATF (to flush and fill). More than 2 quarts if flushing the rack is desired.
• Power Steering Pulley Puller set (to remove and attach the pulley). Some auto parts stores will loan the tool sets.
• Socket set.
• Open end wrench set (for use with puller set).
• Leverage pipe or extension bar (in case the pulley is hardened on the spindle).
• Drain pan (to drain & flush power steering system).
• Wheel bearing grease for sliding pulley on the pump hub.
• 2' wood 1x2 for assistance with aligning the pulleys. Any straight tool will work fine -- a level, metal rod, wood, whatever.

To remove the pulley wheel from the power steering pump you typically have to remove 3 bolts but to get to those 3 bolts you have to use a socket and go through the holes on the pulley itself.

you cannot you have to remove the pump complete

Section 11-02A: Steering Pump, Power, C-II 1996 Aerostar, Ranger and Explorer Vehicles Workshop Manual REMOVAL AND INSTALLATION Pump and Pulley SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Steering Pump Pulley Remover T69L-10300-B Steering Pump Pulley Replacer T65P-3A733-C
Removal

1. Disconnect the power steering return hose (3A713) at the pump and drain fluid.
   

1. Remove the power steering pressure hose (3A719) by unscrewing connector from the pump.
   

1. On the Aerostar 3.0L V-6 engine (6007), loosen the drive belt tensioner (6B209) and adjustment bolts.
   
   
   
   
   
   Item Part Number Description 1 10346 Generator 2 8501 Water Pump 3 8678 Belt Idler Pulley 4 3A733 Power Steering Pump Pulley 5 6303 Crankshaft 6 2884 A/C Clutch 7 — Without A/C On the 2.3L I-4 and 4.0L V-6 engines, slacken belt tension by lifting drive belt tensioner in a counterclockwise direction. On Ranger 3.0L V-6 engines, slacken belt tension by lifting drive belt tensioner in a clockwise direction. Remove drive belt (8620) from under drive belt tensioner and slowly lower pulley to stop. Remove the drive belt from the power steering pump pulley (3A733).
   
   
   
   
   
   Item Part Number Description 1 10346 Generator 2 2884 A/C Clutch 3 3A733 Power Steering Pump Pulley 4 8501 Water Pump 5 6303 Crankshaft 6 8678 Belt Idler Pulley 7 6B209 Drive Belt Tensioner

1. NOTE: If the drive belt requires servicing, refer to Section 03-05 .
   
   Remove the drive belt from the power steering pump pulley.
   

1. Remove the oil dipstick tube.
   

1. Remove the power steering pump support (3C511).
   

1. Install Steering Pump Pulley Remover T69L-10300-B on the pulley.
   

1. NOTE: Do not apply pressure on the power steering pump rotor shaft (3B559). Pressure will damage internal thrust areas of the power steering pump (3A674).
   
   While holding the remover tool nut stationary with a wrench, rotate the inner spindle of the remover tool clockwise until the pulley is pulled off the power steering pump rotor shaft.
   

1. Remove the bolts attaching the power steering pump to the A/C compressor mounting bracket (2882).
   

Installation

1. Install the power steering pump on the A/C compressor mounting bracket. Install and tighten attaching bolts to 41-61 Nm (30-45 lb-ft). On 4.0L engine, tighten to 47-64 Nm (35-47 lb-ft).
   

1. Position the support on the A/C compressor mounting bracket. Install mounting bolts and tighten to 47-64 Nm (35-47 lb-ft).
   

1. NOTE: Fore/aft location of power steering pump pulley on power steering pump rotor shaft is critical. Incorrect belt alignment may cause drive belt squeal or chirp. Make sure pull-off groove on power steering pump pulley is facing front and flush with end of shaft ± 0.254mm (± 0.010 inch).
   
   Install the Steering Pump Pulley Replacer T65P-3A733-C and install the power steering pump pulley.
   

1. Install the drive belt on the power steering pump pulley.
   

1. On the 2.3L I-4, Ranger 3.0L V-6, and 4.0L V-6 engines, position and rotate drive belt on engine. While lifting drive belt tensioner in a counterclockwise direction (clockwise on Ranger 3.0L V-6), slide drive belt under drive belt tensioner and lower drive belt tensioner to drive belt.
   On Aerostar 3.0L V-6 engine, position the belt idler pulley (8678) assembly to give the drive belt the tension specified. Refer to belt tension check in Section 03-05 . Tighten the drive belt tensioner and adjustment bolts to 47-64 Nm (35-47 lb-ft).
   

1. Install the power steering pump support, if removed.
   

1. Install the oil dipstick tube.
   

1. Install the pressure hose tube nut and new Teflon® wagner into power steering pump valve outlet fitting (3D654) and tighten to 41-54 Nm (30-40 lb-ft).
   

1. Connect the power steering return hose to the power steering pump, and reposition the clamp.
   

1. Fill the power steering oil reservoir (3A697) with Premium Power Steering Fluid E6AZ-19582-AA or equivalent fluid meeting specification ESW-M2C33-F. Start the engine and turn the steering wheel (3600) from left to right without hitting stops to remove air from the system.
   

1. Check for leaks and recheck the fluid level. Add fluid if necessary to proper level as specified in Section 11-00 .
   
   
   Power Steering Pump and Power Steering Pulley, 2.3L TPH Engine, Ranger Only
   
   
   
   
   
   Item Part Number Description 1 2882 A/C Compressor Mounting Bracket 2 N606543-S2 Bolt (2 Req'd) 3 N606069-S2 Bolt (2 Req'd) 4 N605803-S2 Bolt 5 N800199-S8M Screw 6 3D673 Power Steering Pump Pulley 7 3F671 Power Steering Belt Idler Support 8 N806020-S2 Bolt 9 3A674 Power Steering Pump 10 19703 A/C Compressor A — Tighten to 21.2-29 Nm (16-21 Lb-Ft) B — Tighten to 40.3-55 Nm (30-41 Lb-Ft) C — Tighten to 44-51 Nm
   (32-38 Lb-Ft)
   
   Power Steering Pump and Power Steering Pulley, 3.0L Engine, Aerostar
   
   
   
   
   
   Item Part Number Description 1 3A674 Power Steering Pump 2 3C511 Power Steering Pump Support 3 6007 Engine 4 N803564 Stud 5 N802827-S2 Nut 6 N800199-S8M Screw (3 Req'd) 7 N8011179-S2 Screw (3 Req'd) 8

I have changed the pump out on my wife's 99 Voyager, 3.3 liter. Per my manual (and experence) there should be a nut at the back of the pump connecting it to the bracket. Then there are three (3) bolts which connect the pump to the bracket (front of pump under pulley. I my memory serves part of the front bracket will have to be removed with the pump. Lastly, if a 3.3 or 3.8 V6 you;ll have to remove the exhaust where it connects to the back manifold (has a flex pipe to it. Trust me on this the manual is correct with removing the ehaust from the engine, I tried to prove the engineers wrong but its the only way out and back in. Plan for these four (4) bolts to break and replace with new when putting pump back in, use new exhaust gasket too. To remove/install pulley to pump you'll need a special puller, cheap to by or may be rented.

I hope this may have assited you,
Tom

REMOVAL & INSTALLATION

See Figures 2, 3 and 4

1. Position a fluid catch pan under the power steering pump.
2. Disconnect the feed and return hoses from the power steering pump, then drain the excess fluid into the catch pan.

On models equipped with a remote fluid reservoir, disconnect and plug the hose(s) in order to prevent system contamination or excessive fluid loss.

1. Remove the drive belt from the pulley.
2. Install a puller tool such as J-25034, or equivalent onto the power steering pump pulley. While holding the pilot bolt, turn the tool nut counterclockwise in order to press the drive pulley from the pump.

When installing the puller tool onto the power steering pump pulley, be sure that the pilot bolt bottoms in the pump shaft by turning the head of the pilot bolt.


Fig. Fig. 2: Installing the pilot bolt


Fig. Fig. 3: Removing the power steering pump pulley


Fig. Fig. 4: Installing the power steering pump pulley

1. On most models, it may be necessary to unplug the electrical connection from the A/C compressor, unfasten the compressor mounting bolts and set the compressor to one side without disconnecting the lines.
2. If equipped, unfasten the power steering filler tube bolt and remove the filler tube.
3. Remove the rear brace retainers and the brace.
4. Remove the power steering pump-to-bracket bolts and then remove the pump from the vehicle.

To install:

1. Position the pump to the vehicle and secure using the front retaining bolts to 22 ft. lbs. (30 Nm) 2.2L engines. (50 Nm). On 4.3L engines tighten the bolts to 37 ft. lbs. (50 Nm).
2. If equipped, install the rear brace and tighten the retainers to 22 ft. lbs. (30 Nm) on 1994-98 2.2L engines. On 1999 2.2L engines, tighten the brace retainers to 37 ft. lbs. On 1994 4.3L models tighten the retainers to 24 ft. lbs. (33 Nm). On 1995-99 4.3L models, tighten the retainers to 31 ft. lbs. (41 Nm).
3. If removed, install the A/C compressor.
4. If removed, install the filler tube and its retainer. Tighten the retainer to 15 ft. lbs. (20 Nm).
5. Use a pulley installer such as J-25033 or equivalent to press the drive pulley onto the power steering pump. While holding the pilot bolt, turn the tool nut clockwise in order to press the drive pulley onto the pump. Check that the pulley is flush within 0.010 in. (0.25mm) of the shaft end.

This requires a special tool; you may be able to rent it

I don't have chrysler producs. I'll post 3.8L V6 Ford Windstar for reference. You'll get some idea.



Removal
WARNING: USE CAUTION WHEN REMOVING OR INSTALLING DRIVE BELT TO MAKE SURE THAT TOOL DOES NOT SLIP.

1. Using a 15mm socket or wrench on bolt attaching drive belt tensioner pulley. Rotate drive belt tensioner (6B209) clockwise to remove drive belt from pulleys.
   
   3.8L Engine
   
   

Item Part Number Description 1 10300 Generator 2 3A674 Power Steering Pump 3 19703 A/C Compressor 4 6B217 Drive Belt Tensioner Pulley 5 6312 Crankshaft Pulley 6 8501 Water Pump 7 6B209 Drive Belt Tensioner 8 8620 Drive Belt
Installation

1. Install drive belt over all pulleys (except drive belt tensioner ).

1. Rotate drive belt tensioner as described under Removal and install drive belt over drive belt tensioner pulley. Ensure that all V-grooves make proper contact with pulleys

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Another example
Pulley, Power Steering Pump CII
SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Steering Pump Pulley Remover T69L-10300-B Steering Pump Pulley Replacer T65P-3A733-C
Removal

1. Drain as much fluid as possible from the power steering pump (3A674) through the power steering oil reservoir (3A697) neck.

1. Install Steering Pump Pulley Remover T69L-10300-B on the power steering pump pulley (3A733) , and place the tool and power steering pump in a vise by gripping the small hex-head of the tool.

1. Hold the power steering pump , and rotate the tool nut counterclockwise to remove the power steering pump pulley . Do not apply in and out pressure on the power steering pump shaft. Pressure will damage the internal thrust areas.
   
   

Installation
CAUTION: Do not apply in and out pressure on the shaft. Pressure will damage the internal thrust areas.

1. Place the power steering pump pulley on the power steering pump shaft, and install Steering Pump Pulley Replacer T65P-3A733-C. The small diameter threads on the tool should be fully engaged in the power steering pump shaft.

1. Hold the power steering pump , and rotate the tool nut clockwise to install the power steering pump pulley on the shaft. The power steering pump pulley face must be flush within 0.25mm (0.010 inch) of the end of the power steering pump shaft.

1. Remove the tool.

1. Fill the power steering oil reservoir to the COLD FILL line.

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Steering Pump, Power Removal

1. Disconnect battery ground cable (14301) .

1. Remove accessory drive belt (8620) .

1. Raise vehicle on hoist. Refer to Section 00-02 .

1. Remove right front wheel (1007) and tire assembly.

1. Remove power steering pump pulley (3A733) .

1. Position drain pan. Remove power steering pressure hose (3A719) and power steering return hose (3A713) from power steering pump (3A674) .

1. Remove four power steering pump retaining bolts (three in front, one in rear) and remove power steering pump .

Installation

1. Position power steering pump and install retaining bolts. Tighten retaining bolts to 41-54 Nm (30-40 lb-ft).

1. Install power steering pressure hose and power steering return hose to power steering pump . Remove drain pan.

1. Press on power steering pump pulley as outlined in this section.

1. Install right front wheel and tire assembly. Tighten lug nuts (1012) to 115-142 Nm (85-105 lb-ft).

1. Lower vehicle.

1. Install drive belt to power steering pump pulley .

1. Connect battery ground cable .

1. Fill power steering oil reservoir (3A697) to proper level. Refer to Section 11-00 .
   
   Power Steering Pump and Bracket, 3.8L
   
   

Item Part Number Description 1 N607528-S2 Screw, M6-1 x 16 2 8509 Water Pump Pulley 3 W804804-S2 Screw, M8-1.25 x 35 4 N806214-S2 Bolt, M12 5 W606691-S36B Screw, M8-1.25 x 35 6 10B315 Generator Brace 7 N621939-S36B Nut, M8-1.0 8 10300 Generator 9 6B212 Accessory Drive Belt Tensioner Bracket 10 6049 Cylinder Head 11 19D624 Air Conditioning Compressor Bracket 12 W606563-S2 Bolt, M10-1.5 x 55 13 19703 A/C Compressor 14 N807273-S100 Bolt, M8-1.25 x 121.5 15 3C510 Power Steering Hose Bracket 16 3A674 Power Steering Pump 17 3C511 Power Steering Pump Support 18 W807239-S8 Bolt, M10-1.5 x 36.5 19 2888 A/C Compressor Brace 20 W806342-S2 Bolt, M8-1.25 x 23 21 W606571-S411 Bolt, M10-1.5 x 113.5 22 6C348 Idler Assembly 23 3A733 Power Steering Pump Pulley 24 N805137-S56 Bolt, M10-1.5 x 157 25 N621939-S2 Nut, M8-10 26 N807241-S36B Bolt, M10-1.5 x 132 27 6B209 Drive Belt Tensioner A — Tighten to 8-11 Nm (71-101 Lb-In) B — Tighten to 20-25 Nm (15-18 Lb-Ft) C — Tighten to 70-95 Nm (52-70 Lb-Ft) D — Tighten to 40-55 Nm (30-40 Lb-Ft) E — Press Flush with End of Power Steering Pump Shaft

you have to remove the pulley get a PS pulley removing tool you will need it to put pulley back on

This removal is rather involved: use a turkey baster to suction out PS fluid,disconnect neg battery cable, remove serpentine belt, raise vehicle, support on jack stands, disconnect Oxygen sensor wiring harness from vehicle wiring harness, (access to this connection is thru the wiring harness grommet in the floor of the vehicle) remove catalytic converter from the exhaust manifold, remove exhaust system hangers/isolators from the bracket on the exhaust system, move the exhaust system as far as possible to the rear and left side of the vehicle, remove accessory drive splash shield, detach the ps supply hose coming from the fluid reservoir, from the fitting on the ps pump, plug the hose to prevent fluid leaking all over, remove ps pressure line from pump, plug this line also, remove ps return hose, plug line, remove nut attaching pump (@ rear of pump) to mounting bracket, loosen 3 bolts at front ps bracket, remove pump and bracket as an assembly, now remove 3 bolts and separate, reverse to install. Yes, it's a b-itch. good luck, countrycurt0