Can part #1 be separated from the aluminum adapter that bolts to the engine block while in the car?
Do I have to remove the complete unit to do a reseal.
The pump is leaking where the aluminum adapter bolts to the block.
I would assume that the seal in Item #1 (pump) failed.
Has anyone removed the pump from these cars.
If give me a heads up as to how difficult the task is.
From what I have read, one of the bolts is a PITA to get to. One poster said he had to make a special tool to extract that bolt.
Anyone?

 

Here is a TSB for the AJ16 engine but the AJ6 is very similar.

bob

 

So a special tool is needed to take the PAS pump apart.
What generic tool is being used for this since I do not know where to get this tool at a cost that is good for a one time use.

 

Since I do not know where to get the "special" tool to take the pump apart, does anyone have a good used pump assembly that they are willing to part with?
Or does someone have the tool that they are willing to rent?
If so, let me know the cost plus shipping to zip 32935.
Thanks

 

The 'Drive-Dog' is pressed onto the shaft.
You can come up with a devise or tool 'cobbled-together' to remove/replace the drive dog on the shaft so the aluminum adapter can be removed/replaced.
I have a shop press in my shop with dozens of plates, tubes, spacers, shafts, shims and all sorts of scrap under the press to pull/push things into/out of place.

A 2 or 3 jaw puller might work to remove the drive adapter and a threaded power steering pulley installation tool might work the install the drive dog?

Get creative and get it repaired!!!

bob

 

MOTORCARMAN: THANK YOU for encouraging me to come up with something to do the job.
You stated "The 'Drive-Dog' is pressed onto the shaft.
You can come up with a devise or tool 'cobbled-together' to remove/replace the drive dog on the shaft so the aluminum adapter can be removed/replaced".

I bought a Harbor Freight bearing puller and modified it to pull the drive dog out.
I cut a bolt and threaded it into the shaft to have something to push against.
I drilled two 1/4" holes as shown in picture and inserted two grade 8 bolts.
Using a piece of metal bent at 90 degrees, I used some crazy glue to hold a nut under the drive dog slot and threaded the bolt into the nut on both sides.
I then tightened the top nut to lock the bolt to the drive dog.
I then threaded in the puller shaft and tightened the shaft down on the cut bolt I had previously threaded into the shaft.
I inserted a bolt into one of the holes in the aluminum adapter and jammed a 3/4" wrench to lock the nut on the puller shaft.
The cross piece started to bend so I made 2 supports to prevent it from bending.
After about 10 turns the drive dog came out.
After separating the pump from the adapter, I took the seals out and went to the auto parts store and was able to find all the seals I needed in a GM kit which actually had more seals because it was for a different application, but the seals I needed were in the kit. See image below.
To re-install the drive dog. I used a long bolt threaded into the pump shaft with various spacers and used two nuts to drive the dog back into place.
Result: Success. Pump works fine with NO leaks

modified puller for XJ40 PAS pump

 

GREAT IDEA

Even when I worked at the dealer I used to make my own special tools. Sometimes because the tools were missing and sometimes because I had a better idea!!

Glad you got it done.

bob

 

I think you are complicating the process,
Just remove the pump together with the adapter and than disassembly the unit starting from the back of the pump
there is a kind of circlip on the back of the pump and the small hole on the side of the body, press the circip through the hole and remove it, remove back cover and the rest should come apart easily
after removing pump internals drive shaft will be free to remove from the adapter side
no special tools required

 

In order to separate the pump from the aluminum adapter, the "drive dog" has to be removed.
Removing the circlip from the back of the pump only gives you access to one O-ring.
To replace the O-rings on the shaft you have to separate the two pieces.
The leak I had was coming from the front seal which is located under the "drive dog"
Refer to the image in POST #1

 

I can't tell you pump arrangement from memory but i did mine by disassembling it from the back, just take your time and inspect the piece properly, possibly there is other circlip on the shaft which keeps the whole thing together remove it and you will be able to pull the shaft from the adapter side and change ALL the seals