How to remove the motor pulley

6) Rotate the motor to the right to relieve the belt tension and remove belt from motor pulley

7) After belt is removed from motor pulley, rotate motor to the left as far as possible to assure cam bar clearance.

8) The spin cam bar must be advanced to the spin position. Push up on the spin control solenoid plunger and rotate the main drive pulley until the cam bar advances to the spin position.

9) Remove the brake yoke spring from the gear case cover and yok. (see figure 2)

10) Remove completely the 3 support braces attached to the gear case and base plate. (see figure 3)

11) Remove the 2 pump mounting bolts. The pump hoses do not have to be disturbed. (see figure 3)

12) Remove the gear case mounting stud which has the spacer. remove spacer (see figure 2). Loosen the remaining 2 gear case mounting studs approximately 7 turns. (see figure 3).

13) Remove yoke retainer from yoke support. (see figure 2 for the types of yoke retainer).

14) The gear case can now be pulled down so that the belt can be slipped out between the top of of the clutch shaft and the clutch yoke. (see figure 4) and then through the space beneath the short stud; drop the belt from around the gear case.

15) Reverse the procedure in steps 15 & 13 to install the new belt.

16) Replace the pump making certain the pump lever is engaged in the notch in the agitator cam bar before securing the pump to the gear case ( see figure 5).

17) Grasp the bottom loop of the yoke spring with a pair of pliers and engage the spring with the hole in the upper gear case cover (see figure 2).

18) Replace spacer in short gear case mounting stud. Tighten the 3 gearcase mounting bolts ( finger tight only ). Next, set the machine upright and tighten the gear case mounting bolts securely. This procedure will allow the superstructure to properly align itself with the center post bearing.

19) Lay the machine on it's front to mount the 3 support braces to the gearcase baseplate. Tighten the bolts securely.

20) To adjust the belt tension properly, position the belt over the pulleys. Insert a hammer handle or some other lever between the motor mounting brackets. Rotate the motor to the left as far as it will go. Tighten the nuts holding the motor mounting bracket. Check the tension of the belt, it should deflect about 1/2 inch. (see figure 1).

21) Set machine upright. Reinstall the agitator, agitator cap, service panel, water hoses and connect electrical supply.

1. Disconnect the negative battery cable.
2. Raise and support the front of the vehicle, then remove the passenger side tire and wheel assembly for access to the rear of the alternator through the wheel well.
3. Working through the wheel well, unfasten the alternator brace-to-block bolt, then remove the brace-to-intake nut and the brace-to-engine stud nut.
4. Unplug the alternator wiring connector, then remove the battery terminal nut and wire.
5. Carefully release the serpentine belt tension and remove the belt from the alternator pulley. Do not allow the tensioner to snap back into position once the belt is off the pulley.
6. Loosen the alternator retaining bolts, then support the alternator and remove the fasteners. Remove the alternator from the vehicle.

1. Position the alternator in the vehicle and loosely install the retaining bolts.
2. On 1994-98 models, tighten the top alternator bolt to 22 ft. lbs. (30 Nm) and the bottom bolt to 32 ft. lbs. (43 Nm).
3. On 1999-99 models, tighten the rear bolt to 37 ft. lbs. (50 Nm) and the front bolt to 18 ft. lbs. (25 Nm).
4. On 1994-98 models, install the alternator brace, then tighten the retaining nut(s) and bolts to 22 ft. lbs. (30 Nm).
5. On 1999-99 models, install the alternator brace, tighten the brace-to-alternator and brace-to-intake retainers to 18 ft. lbs. (25 Nm). Tighten the brace-to-engine stud nut to 37 ft. lbs. (50 Nm).
6. Install the battery terminal wire and tighten the retaining nut, then engage the alternator wiring connector.
7. Hold the serpentine drive belt tensioner, back off the belt while slipping the belt over the alternator pulley. Gradually lower the tensioner into contact with the belt, then check for proper alignment and tension.
8. Connect the negative battery cable.

1. Disconnect the negative battery cable.
2. Remove the air inlet duct assembly, if necessary.
3. Carefully relieve the serpentine drive belt tension, then remove the belt from the alternator pulley. Do not allow the tensioner to snap back into position once the belt is off the pulley.
4. Remove the nut retaining the radiator hose brace to the back on the alternator.
5. If equipped, unfasten the retainers, then remove the brace from the engine and/or the alternator.
6. Disconnect the battery terminal boot wiring from the back of the alternator, then unplug the regulator wiring connector.
7. Support the alternator and remove the mounting bolts (usually 2) from either side of the alternator, then remove the alternator from the vehicle.

1. Position the alternator in the vehicle and loosely install using the mounting bolts.
2. If equipped, loosely install the brace to the engine and/or alternator.
3. Tighten the left or front alternator retaining bolts to 36 ft. lbs. (50 Nm), the right or rear alternator bolt to 18 ft. lbs. (25 Nm), the brace bolt to 18 ft. lbs. (25 Nm) and/or the brace nut to 22 ft. lbs. (30 Nm), as applicable.
4. Connect and secure the alternator wiring.
5. Carefully relieve the serpentine drive belt tension and position the belt over the alternator pulley, then slowly release the tensioner into position.
6. If equipped, install the air inlet duct assembly.
7. Connect the negative battery cable.

1. Disconnect the negative battery cable.
2. Disconnect 2 alternator and voltage regulator electrical harness connectors at the alternator. To disconnect push-on type terminals, depress the lock tab and pull straight off.
3. Remove the positive battery cable nut and remove the positive battery cable at the alternator.
4. Rotate the drive belt tensioner away from the drive belt and remove the drive belt from the alternator pulley.
5. Remove 3 alternator retaining bolts and remove the alternator.

1. Place the alternator on the engine and install 3 alternator retaining bolts. Tighten the bolts to 18-22 ft. lbs. (20-30 Nm).
2. Rotate the drive belt tensioner away from the drive belt and install the drive belt on the alternator pulley.
3. Connect 2 alternator and voltage regulator electrical harness connectors.
4. Connect the positive battery cable to the alternator and install the nut and washer. Tighten the nut to 84 inch lbs. (10 Nm).
5. Connect the negative battery cable.
6. Start the engine and check for proper charging system operation.

1. Disconnect the negative battery cable.
2. Rotate the drive belt tensioner away from the drive belt and remove the drive belt from the alternator pulley.
3. Detach the electrical harness connectors at the alternator assembly.
4. Disconnect the positive battery cable and remove the nut and washer.
5. Remove 2 front alternator bolts.
6. Remove the rear alternator support bracket retaining bolts and the support bracket.
7. Remove the alternator from the vehicle.

1. Place the alternator in position and loosely install 2 front alternator retaining bolts.
2. Install the alternator bracket and 3 alternator bracket bolts. Tighten to 84 inch lbs. (10 Nm).
3. Tighten 2 front alternator retaining bolts to 19 ft. lbs. (26 Nm).
4. Connect 2 electrical harness connectors to the alternator assembly.
5. Connect the positive battery cable and install the nut and washer. Tighten the nut to 72 inch lbs. (8 Nm).
6. Rotate the drive belt tensioner away from the drive belt and install the drive belt on the alternator pulley.
7. Connect the negative battery cable.
8. Start the engine and check for proper charging system operation.

1. Disconnect the battery ground cable.
2. Label and detach the connectors from the alternator.
3. Release the tensioner and remove the drive belt from the alternator pulley.
4. Remove the alternator retaining bolts.
5. Remove the alternator from the vehicle.

1. Position the alternator and install the retaining bolts. Tighten the retaining bolts to 15-21 ft. lbs. (21-29 Nm).
2. Install the drive belt.
3. Attach the alternator connectors.
4. Connect the battery ground cable.

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
   
   

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

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.
   
   

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.

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 .

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