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Sorry to post a new thread on this so soon , but I wanted to try to get a conversation going about the power steering pulley wheel on late-80s Comanches with 2.5L engines. My issue is minor but annoying. The power steering pump works, but it makes noise, specifically a clicking noise. I did a bunch of reading last night — including of old parts manuals. It seems like the 1987-1990 and possibly 1991 MJ, XJ and SJ’s with the 2.5L and power steering, came with a pulley wheel that is hard to find these days. The part number is 5300 3805 for those who are interested. I have some questions about this, and if we can answer them all in one thread, it could be really helpful to anyone troubleshooting their power steering on an ‘87-‘90 (and maybe ‘91) MJ, or other similar jeep with a 2.5L + power steering. QUESTIONS: 1) Does anyone know why other similar pulleys cause issues on the ‘87 and other adjacent years with the 2.5L? And before you answer, I understand that they don’t line up quite right. But does anyone have details or theories about how/why they don’t line up? Are they too far forward? Too far back? Is the angle off? Are the ribs on the pulley not quite right? All of the above? 2) If someone like me can’t find the exact OEM part or parts, has anyone had luck with making other parts fit? What did you do? Did you put spacers behind the bracket, for example? 3) In my case specifically, the pulley wheel I am currently using is marked G3 53002909. I think it came off a YJ, but maybe something else… with this particular pulley wheel, is there something I can do to fix my issue (which is a clicking sound)? DETAILS & PICS: - Pump Style: I have this style of pump. It’s the kind with a remote reservoir. - Belt Position on Pulley: Here is how the belt sits on the pulley. I tried scooting the wheel forward on the wheel, but it didn’t make a difference. Probably because the grooves hold it in place. - Rough Grooves: I was originally thinking that the rough spots on my pulley wheel’s grooves were playing a part in this. And maybe they are. I tried my best to file/sand them smooth. Before: After:

Hey all! Before I go through the trouble of pulling my power steering pump again, I wanted to consult the community. I've got a clicking sound that seems to be related to the belt, a pulley wheel, or something like that. I am fairly sure that I've isolated this issue. I'm 90-ish% sure it is something related to the power steering pump. So, over this past weekend, I replaced my pump. The symptoms seem to have improved, but it's not fixed. I don't want to drive the truck too much until I get this fixed, because I'm worried that this is an issue that will get worse over time. The Issue: Clicking Noise Speeds Up & Slows Down w/ RPM I first noticed this shortly after I had power steering installed. I would post a video, but I bet the moment I pull out my camera, it won't make the sound. Plus I find that engine noises don't translate that well over phone cameras. Essentially, it is a click. I don't think it's a chirp, although it's kinda like a chirp. But let's call it a click. And it speeds up or slows down with engine speed. What I've Done So Far - I've done the water/soap test. That seems to make the noise go away. - I've run the engine without the belt hooked up: No clicking noise. - I've replaced the pump (just the pump... not the gearbox). I did this because after I took the belt off, I observed that the pulley seemed to wobble a bit. Kinda like the pulley shaft was loose or not fitting right into the pump housing. I figured it might be a bad bearing. I thought about just replacing the bearing, but that seemed like a ton of work and I realized it could have been a busted vane or something else, so I just replaced the entire pump. What I Haven't Done I have not tried to run the belt without the Power Steering Pump connected. That would involve reinstalling the old flywheel that was in pump's place. I may try to do so next weekend. I have not tried to install a new belt or treat the belt with some kind of product. I have not tried a new pulley wheel (I think this my next step). The current pulley wheel is kinda beat up. My Questions Anyone Experience This? If so, were you able to fix it? Pulley Wheel Recommendations? I see a lot of different pulley wheels at a lot of different price points. Belt Tension: How much do I need to obsess over belt tension? Got recommendations for a quality belt tension measuring tool that won't break the bank? I've just been doing belt tension by the Goldilocks Method. Not too stiff not to loose. But maybe I need to step up my game. Pulley Alignment: How much do I need to obsess over pulley wheel alignment? My current theory is that the clicking has something to do with the pulley wheel itself. It's kind of beat up and has a few chips in the grooves. I also thought that maybe I need to be more obsessive over the alignment of the pulley wheels. I know that there are laser pulley wheel alignment tools but the ones I've seen so far are expensive! If I can rent one, I would be willing to do that to get the alignment perfect. Better Power Steering Pumps: I'm currently running a TruGrade pump #7081. I think that is what was in there previously, as well. It seems like there were two types of pumps that Jeep used originally. One was the "Ham Shaped" one. That is not the one I have. Picture of my pump is below. Maybe I need to get a different type of pump? This is the pump I'm currently running. Napa Auto Parts says this is the only one that fits my vehicle. There are other types of PS pumps (but maybe they are for the 4.0, and I have the 2.5). This is the other style of pump:

Quick question (hopefully). Putting a new power steering pump in my 90 Comanche, 2.5l. When I disconnected the old PS pump high pressure line (top finger) this is what it looked like. New pump looks like bottom finger. I assuming i just need to take the nipple with the o-ring off the old high pressure line, then that long cylinder before the bigger nut will go in the pump, right? Any help is appreciated! Thanks

I have a 91 Comanche 4.0. Just installed a high output intake plenum. Now power steering pump mounting bracket doesn't fit. Is there a different bracket for this set-up~?

Well, I guess this is the start to my build thread! won't really be a build just the progress of my daily. I’ve had her for like 2 months now and so far ive: Replaced both window regulators Fixed a lower radiator hose leak Got a steal on new taillights Did front breaks New tires Window tint Right now I'm working on chasing down a TCU problem. My trans isnt shifting on its own so I have to go 1-3-4. I’ve got some big plans for this truck in the future its just a matter of saving up! If you want to follow the build closer follow my insta @ DannyD815 I will add more photos when I can!

Have a 86 comanche 2.8 ltr 4wd automatic when i bought the vehicle it had no 2.8 ltr LR2 motor in it so i put in a 3.4 ltr L32 motor in it I'm trying to figure out how the power steering works if anyone has pics of how the power steering hooks up and what it all connects to would be great i don't know where to connect the hose lines from the P.S. pump but i do have the pump connected to the motor

Hello i am restoring a 86 comanche 2.8 ltr 4wd automatic when i bought the vehicle it had no 2.8 ltr LR2 motor in it so i put in a 3.4 ltr L32 motor in it i am at the part where I'm trying to get the tranny to work and I'm trying to figure out how the power steering works if anyone has pics of how the power steering hooks up and what it all connects to would be great i don't know where to connect the hose lines from the P.S. pump but i do have the pump connected to the motor also where is the drain plug on the tranny i think i put to much fluid in it because it slips i have the 3-speed A904 automatic tranny i was also having a hard time reading the dip stick to the tranny where exactly is the line that tells you when its full i did read in the haynes manual that the truck must be running in order to check the fluid level if you guys want pics i can post some upon request Thanks

I know lots of people add power steering but how could I remove it just switch to manual. Can i just remove the pump cap the steering box and throw a shorter belt on or do I have to replace the steering box with a manual one. The main thing is i don't want to spend the money to replace the leaky steering box. or should i just suck it up and do it?

Does anybody know where I can find just the O-rings for the hydraulic lines that run to the power steering box? I have a slight leak coming from the return line fitting. I replaced the high-pressure line a few months back (which came with a new O-ring for it). Now I just need one for the low-pressure side.