PS Pump fail again!!

[RustyNut]

Very frustrated today. Just got the car running properly after finally getting the 044 pump fitted, out on a test drive, all good, pulling really well then a mile from home noticed a bit of smoke coming from the front end. Assumed it was just some spilt oil or whatever being burnt off so headed home slowly just incase. Got to my drive, turned the wheel and the ps pump was squealing. It then started constantly whirring and when I pulled up to my garage the steering was seriously heavy, juddering and making an awful noise... Lots of smoke too... Opened the bonnet and there was PS fluid everywhere!!!! This is the third failure after the third rebuild of the pump! I'm now thinking the pump is being over loaded by something (not sure what) because the exact same thing happened with a replacement that was working perfectly when removed from the previous S2 as well as after the previous rebuilds. I've read there's a filter or gauze in one of the pipes but really not sure where this is? Could this be blocked and causing the system to over pressurise? If not is there any other gremlin that may be causing the system to over pressurise? Was hoping to put her away for the winter but now have a load of engine bay cleaning and pump replacing to do, again! Any ideas chaps? Really want this issue to end because the rest of the car is perfect now.
Cheers
Russ.

[Rusty]

Ah crap, not the ultra clean engine bay?

Why not just fit the secondhand pump you have, or is that the one that's fubar? If it's the same pump that's been rebuit 3 times, then just ditch it and see if you can get your money back for the rebuilds, as they're obviously not up to scratch

Other option is to get an electric pump and go vac assist on the brakes

[Rocco]

Are the power steering pumps still rebuildable?

Russ, be careful with the liquid, clean it quickly because is corrosive!

[Rusty]

Russ went as far as removing his engine to clean the engine bay, so lord only knows what lengths he'll go to to clean up the mess

[Error404]

Marine Clean will make short work of it

There is a non-return valve in the banjo bolt on the PAS pressure line from the pump to the rack, its possible it is damaged. You will also find the other banjo bolts on the PAS system have gauze in them, so they probably could do with a clean, especially if you have had pump failures before, there will certainly be crap in the system.
I would remove the PAS hoses and banjos and give them a thorough clean & blow out.
Fit a different working pump and thoroughly flush out all the hydraulic fluid (hose return from the rack into a bucket and then run the engine and keep adding fluid until it runs out clean, then flush another litre of fluid through it).
Run the car at idle and monitor the temperature of the pump - they get hot really quickly if there is a restriction in the system that the pressure relief valve can't handle - once the fluid overheats the pump gets noisy and soon after it is pretty much toast.


HTH
Alex

[RustyNut]

I've gotten most of it off with a load of paper towel and some AG engine cleaner. I remember you recommending the POR15 at coombe Alex, is it safe to use on paint etc? The fluid has made its way on to the belts as well so would need to give them a good clean too so just need to be sure it's not going to damage anything? Is the application and rinse method pretty straight forward from your experience?
Regarding the main issue I would ideally need to run the car and see where the leak is coming from and may then be able to isolate the problem area. Just need to remember the best point to drain from. Does the pump need to come out again do you think? To start with I'll just run her and find the leak point and I'll start to disassemble as required. So bloody annoying this...

[Error404]

Marine clean is safe on paint but worth going over with some wax or polish afterwards as it will strip any existing wax or protection off it
Mix it up with hot water so you can control the strength of the solution, you don't need much. work it in with a soft brush and leave it for a few mins. Then just rinse off with cold water.

My guess will be the fluid comes pissing out the front as the housing is worn (there are no bearings, the shaft is supported by the housing itself, which is why it damages them really easily if they overheat). If this is the problem, you can repair it but you need to find a good engineer who will bore and sleeve the housing and then ream / hone to size. Almost all pumps of this age will have some kind of wear and I believe this is why these pumps hardly ever benefit significantly from a generic "rebuild".

FYI the pump is really easy to strip down except for the triangular pulley flange which needs to be pulled / pressed off the shaft to get it out of the front housing.

[caterpillar]

psst; what PS fluid are you using...??? the org audi stuff or??

[Rusty]

Febi 6161 to G002000.

[Rikki Kitto]

Know the feeling well, mine chucked it's guts up three times in as many weeks down to poor seal on the top. very frustrating now it sounds like a sewing machine

[RustyNut]

Just been checking for any other causes for my recent ps pump failure and just need a bit of info/input to double check a couple of things. 1: How do you check for the correct fluid level and is it possible that over filling could cause the pressure to build excessively and blow the seals? Was chatting with Pete at QC and he said that if the system is the same as the UR one you check the fluid level by pressing the brake and the fluid will rise in the reservoir and stop thus indicating fluid level? 2: If the system is connected to the braking system could someone explain in simpleton terms how the two are connected? I want to check everything and explore every possible cause as it's likely that I'm just going to have to sell some more of my bits stock and buy a new pump now and I don't want that failing too! From what Alex has said reference rebuilds and the lifespan of the unit I think cost wise and for the sake of my sanity I'm probably better off buying a new unit. Has anyone bought a new pump recently for a decent price or know of anywhere that do them for a decent price and what I should reasonably expect to pay for one?

Cheers

R.

[jade]

Just been checking for any other causes for my recent ps pump failure and just need a bit of info/input to double check a couple of things. 1: How do you check for the correct fluid level and is it possible that over filling could cause the pressure to build excessively and blow the seals? Was chatting with Pete at QC and he said that if the system is the same as the UR one you check the fluid level by pressing the brake and the fluid will rise in the reservoir and stop thus indicating fluid level? 2: If the system is connected to the braking system could someone explain in simpleton terms how the two are connected? I want to check everything and explore every possible cause as it's likely that I'm just going to have to sell some more of my bits stock and buy a new pump now and I don't want that failing too! From what Alex has said reference rebuilds and the lifespan of the unit I think cost wise and for the sake of my sanity I'm probably better off buying a new unit. Has anyone bought a new pump recently for a decent price or know of anywhere that do them for a decent price and what I should reasonably expect to pay for one?

Cheers

R.

Your brake circuit will not affect the hydraulic system which offer assistance via the servo which is between master cylinder and top of the pedal if the servo fails it will leak and offer no assistance, if your steer is not acting up every thing is probably fine

I have rebuilt a few of these pumps when rebuilding you need to replace the cross screws with new ones they come as a kit otherwise they seem to fail.

Also the pumps I have rebuild have still been noise I too am looking for a solution

I hope this helps

[zefsider]

I had this saved to my Watch list on ebay, but since I replaced my cross plug/seal I think mine might be OK (watch it fail now ! ) Dunno if cheap, but as a rebuild seal kit is , what, £60 ? then I guess that it may be worth it ?

http://www.ebay.co.uk/itm/3309359934...84.m1438.l2649

[RustyNut]

Thanks chaps. Pete at QC does them for that price also which is where I'll be getting it if I go down that route.

[zefsider]

nice to know they are not more than that price and readily available ...I had nightmares that they were n/a or £+++ which is why I was keeping that link in my back pocket ;-) ....even so, £200 isn't cheap by any means....cheaper than brake fail though eh ! I still stand by the old advice of soaking seals in PS fluid for 24hrs before any rebuild