Hi All,

I've been trying to figure out where my 03 2500 4x4 has been leaking PS fluid from. Went out today and replaced the OEM clamps on some of the hoses with standard hose clamps (at the suggestion of posts in this forum) but I don't think that was it. I pulled off the wheel well shroud to get a better look and figured out that fluid is coming from somewhere on or around the pump itself. The bottom of the reservoir is visibly wet with fluid, while the sides and top are dry/clean (relatively speaking). The pump is questionable. The hoses and gearbox, which is directly underneath the reservoir/pump, are wet to varying degrees. That tells me that the pump and/or reservoir is the problem. Although the hoses are damp with fluid, none seem to be leaking.

I also noticed that the reservoir is not tight to the pump. I can actually move the reservoir in its bracket about 1/8 inch. Is that normal or should the reservoir be tight to the pump?

Thanks for any thoughts or advice in advance!

 

Might not be much help but I had my pump replaced about 6 months ago and just replaced the cap on the reservoir yesterday, the seal in the cap was bad.

 

Thanks Bswope, but the reservoir cap is fine. Dry all the way down to the bottom of the reservoir.

 

Check the middle nut on top of the steering gear. If its loose it will leak. I've already replaced my steering gear twice with only 56K miles. The internal seals could be shot and that why its leaking too. If you replace the steering gear get a after-market steering gear brace. This keeps the sector shaft from side loads due to frame flex and/or side loads from the pitman arm during use.

 

Don't discount the cap yet. Both of my '03s had problems with the cap not venting. It's designed to vent, and if it is then you normally won't have any leaks. Pressure will just find the easiest way out. That's why the o-ring on the reservoir is where it appears first. Get it warm or the next time it's leaking and warm, shut it off and open the reservoir. See if the cap "pops" off of if it just comes off. If it pops it will spray a little so be ready for it. HOT fluid. If this is the case then look at the cap and you can see where it vents under the rubber seal. Lots of brake clean will clean it well. It shouldn't come back for a while. Best of luck.


Chris

 

Thanks Chris. I'll check. The cap on reservoir does "pop" off when opened. Seems to build quite a bit of pressure. If I understand you right, the cap venting prevents too much pressure which would lead to leaks?

Does that mean that the "loose" seeming fit of the reservoir into the pump is normal?

 

pressure wash the whole area real well, then inspect it after a few miles then reinspect it again.
Those caps are a real seal killer.

 

Bingo.

Since you already confirmed on the "pop", then do the cleaning, or if you're careful you can get the dipstick part out and you'll see the little vent port. Enlarge it just a little bit to help delay this happening again. As far as the looseness, it would do you good to replace the o-ring on the reservoir. You can't get it at the dealer, so you'll need to go to a NAPA or a real parts house. The usual chains won't be much help. A tractor or hydraulic store is a better choice. The o-ring will appear squared off instead of rounded. That's normal with time and your replacement will look the same in a few years. Oh, BTW, I had to do this little task of cleaning the cap every few months. It does help though.

Chris

 

ratlratl
How do you separate the lid from the dip stick to clean the vent ports ?
Thanks

 

use a small tipped screw driver to pry the top and the dip stick apart. once seperated, you'll see a small rubber plug/plunger that is supposed to float around.
remove it and grind down the material on the cap itself to allow more room for the rubber plug/plunger to move around.

you may find more info on this doing a search. i did this to my 06 for the same issue

 

There are two O rings between the Reservoir and the pump and after I did the cap thing and the Oring on the cap thing and washed the whole area of the PS pump I finally pulled the reservoir off and replaced the orings between the pump and the reservoir and it has been fine for over a year and a half now.
Jim O