Pos Pas!

[Henka]

When I bought the car it was leaking from one of the plugs (bung??) on top of the P/S pump. Now... I changed the plug, made a special tool for the plug and tightened it. I think it was tight enough and didn't leak. Later I noticed oil ON TOP OF the plug. No to me, that means I have a leak from the banjo. This morning it was cold outside, like -20 degrees celsius. The red (o) alert came on, popped the hood and voila - no oil in the reservoir. So. What do I do now?

I checked some of the threads (Alistair E's first was the last one!) and they mainly concern internal leakage due to endplay - but my pump isn't leaking internally is it? I mean, i can see hyd oil on the pump and below it on the eng block.

The previous owner had changed a plug about 6 months before I bought it. That plug was nowhere near tight and I though (hoped) that changing the plug and tightening it with my home-brewed-special-tool would do the trick. I noticed that the lower seal of the banjo was worn but I didn't regard it as a problem. Maybe it is?

What do I do? I can afford a new pump but I'd sure like to fix mine instead. I mean, I'd rather buy something else for the cash. It's not leaking from the front seal but maybe from the plug or banjo? Internal leakage? Can that cause somekind of excess pressure on the plugs and seals causing them to break?

C'mon... I don't want to change the pump...

[4WheelDrifter]

IIRC the hydraulic system operates at a very high pressure. So I'm guessing, if there are any worn seals, or plugs or banjos not tight, then the system could easily leak.

[Graham]

This plug is changeable, Fourrings had exactly the same problem, and there is a kit you can buy to replace the plug and seal underneath the plug.

[Henka]

As I stated above, I've changed the plug once. Now I'm afraid it's leaking again. I'm picking the pump apart next week on monday.

[Jeffer]

Had the same problem 4 years ago. I made a tool that fitted exactly in the + shape and I loosened the bolt/plug. Then I used a copper washer that flush fitted in the champer where the O-ring sits. After I made it fit perfectly I heated the copper washer (annealing). When its cooled I fitted the bolt/plug again, and tightend it with my homemade tool. After 4 years it's still not leaking (touch wood).

HTH,
Cheers

BTW I made the tool with 2 flat steel bars that I welded together to form the plus shape

[Henka]

So I took the pump apart today. It wasn't leaking from the plug but rather from the seal around the drive shaft. Now, I only took the first part apart, the pump itself I left alone. I have a big axial play and I'm guessing this has caused my seal to blow. Question is - do I need to open up the pump? Why do I have an axial play? What is worn? I mean, I can shim it but what is worn?
What play should I have? I'm guessing 0.1mm is sufficient?