Jeff_032500_WI

I realize I may not be asking this question in the right place, but my truck is an 03 quad cab 4wd with the 5.7 hemi and I haven't found the answer to my questions, so I'm asking here as I don't know where else I should be asking.

Because my steering sucked, I purchased all the steering components off a low mileage 2014 2wd 2500 with the gas engine from a junk yard. I had already put the T style linkage on my truck, so I really only used the steering box with pitman arm, the pump with pulley (ZF pump with larger shaft than the stock pump on my 03), steering shaft, and some of the lines. I actually bolted all this together and ran the truck all winter before having a stock 2003 style serpentine belt shred. It was at this point that I noticed the 2014 power steering pump pulley had 6 ribs and all my 2003 pulleys and belt were 7 ribs!

I researched this issue on line and did NOT find very much information, however, I did see mention of a Dorman 300-149 pulley, so I bought one. It fit on the pump fine, but was much larger in diameter than the 2014 pulley and prevented the pump from bolting back up to the engine due to interference with the crank pulley. It also had one additional rib (8) compared to the stock 2003 setup (7).

After more research, I thought I had stumbled upon the right pulley. Dorman 300-012 which had the correct shaft diameter (.66"), the correct rib count (7), and the correct diameter (5.5")! However, it would not fit far enough onto the pump to align with the 2003 accessories. Having no other options that I could find, I ground the back of the pulley (plastic with a metal center) approximately 1/8" to create a flat back side of the pulley. Once pressed back on the pump as far as it would go (back of center metal piece is right against the pump seal and the outer edge of pulley is just about hitting the output fitting), it still appeared to be about 1/8" off from proper alignment. Having no other ideas, I threw another new stock 2003 belt on the thing and it's been working fine even though it's only been a day.

My research suggests the following:

03-08 gas engines used a K071013 7 rib belts with S8005 belt routing
09-15+ gas engines used a K060795 6 rib belt with S7026 belt routing

The ZF pump started being used on the 5.7 in 08 and car-part.com suggests this is the only year that used the 7 rib pulley

Car-part.com suggests 09-10 5.7 2500's used something different from the 08's

Car-part.com suggests 11-13 4x2 5.7 2500's used something different again

Car-part.com suggests 11-16 4x4 5.7 2500's used another unique setup again

If anyone has further information, I'm all ears! Jeff