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It's always something - PS rack leak issue (long)
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Posted by MS (more from MS) on Wed, 10 Apr 2002 00:27:51 Share Post by Email
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For some time I've known about my serious PS fluid leak. The upper pinion shaft seal to be exact. Determined to keep costs down I opted to replace it with a known good one. A good one is one that doesn't leak. I found just such a piece last week and spent close to 7 hours last Saturday installing it. The first problem issue I encountered was being able to remove the old rack, then reinstall the new rack from below with the engine in place. The donor car from which I pulled the leakless rack had no engine to deal with.

I discovered that the left side tie rod end was perhaps an inch too long to pass below the engine compartment chassis even with the right side fully extended out the right side hole. Once that tie rod end was below the engine compartment, the entire rack would fall free. I ended up having to put the rack back in place with semi-tightened bolts, and reattach the end to the steering knuckle so as to loosen the tie rod end securing nut, thus enabling the removal of that tie rod end. After doing that the old rack slipped out easily.

The installation of the "new" rack went smoothly, all hoses secure, plus I even had a "newer" used PS fluid pump unit (the 8V variety). All seemed fine until the following morning when I looked to find the fluid reservior was nearly empty and a pool of fluid on the ground below the general vacinity of the pump. Back up on the ramps, I filled the fluid tank and crawled underneath to watch. Sure enough, a slow drip formed somewhere at the bottom of the pump. OK, so I had a bad used replacement pump.

I reinstalled the original. And guess what? The same friggin leak! That meant one of the hoses near the connections perhaps. With a clean rag I touched along the connection areas, but they were sound. I then reasoned that on both pumps the failure/leaking had to be from the same spot. But where exactly? With the unused pump I rigged up a way to seal off the two (in/out) openings, filled the thing up, cleaned all exterior surfaces and watched to see where the leak came from. Bingo! It was coming from the bottom of the reservior tank along the pressure seam (two metal components pressure fit together) lip. Specifically the pulley wheel side.

What to do? Well, from what I could determine, this was a perfect job for JB Weld! And that's just what I did earlier today. I cleaned away any evidence of fluid/oil with carb cleaner, then placed a nice bead of JB along the seam. I'll know tomorrow if this fixed it. I'll wager it does.

This will be the third use of JB Weld on this car. The first being along the bottom lip of the aux air valve where there was a considerable air leak. The second being to fill in the pitted cylinder head surfaces just last week.

My back and hands are killing me, but my wallet thanks me.

posted by 205.188.199...
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