Finally got the new power steering pump. Yesterday I went and bought the last 3 quarts of Valvoline ATF4 that Walmart had so I was ready to tackle the job.
The pump actually went back on easier then getting it off. I bolted the pump on and then put the belt back on before connecting the hoses. I just used a 3/8" ratchet and cheater pipe and was able to slip the belt partially on with my other hand and then used a long piece of wood to finish getting into place. I primed the pump with some ATF-4 transmission fluid before putting the hoses on. Put the hoses on and the rest of the air intake before firing it up.
I decided not to try and attempt to flush any of the system. When I called the Jeep dealer I asked him about how to flush the system and he kind of laughed and he said it complicated, you need specialized equipment and he said "most people don't fool with it" which I interpreted to mean that they don't do it.
Yesterday was able to get some more out of the system, I went to Lowes and bought a roll of the smallest fuel line used on small engines and it fit down the last section of hose that I hadn't been able to evacuate. I got another 4-5 oz of fluid out with the only thing left in the rack and pinion steering, it would take quiet a bit of flushing to purge that and with the 5.7 Hemi there is just not much room and this is compounded by the fact that there are hoses going the hydraulic fan cooler.
So I filled the reservoir and started the engine just for a couple seconds and confirmed it was pulling fluid from the reservoir, added some more and started it back up, shut it down and checked a couple more times. There was some air in the fluid initially but it became clear after awhile. Took it for a test drive and all is good. Fluid in the reservoir looks good, same color as came out of the bottle so if there was some old fluid it must not have been much.
So it cost me ~$130 to change the steering pump with pulley, I did buy an after market off the internet and it looked exactly like the one I took off. None of the local auto stores had it in stock and they wanted much more.
So my 2005 Jeep GC w/Hemi has ~145K miles on it. I bought it used ~11 years ago and have put about 60K on it and have probably pulled it another 50K. It is starting to show it's age though. This year alone I've had to
- Change the radiator/water pump,
- Replace the rubber section of the transmission cooling lines since they were weeping. Service the transmission.
- Replace the front rotors and brake shoes all around
- Spark Plugs and O2 sensors since it threw the code.
- Changed the Steering Pump
So hopefully it's ready to go a while and considering the cost of new ones I'm willing to continue to baby it.