Power Steering Leak WTF!?!?

[freerider15]

Alright, so I'm working on getting my '98 XJ fixed up and ready for sale.

I went to do a power steering flush, and long story short I ended up having to buy a new reservoir.

So, I got one of the Dorman reservoirs.

I for the LIFE of me can not get the system to stop leaking. I'm 99.9% sure it's coming from between the reservoir and pump, as most people have issues with it.

I know most say the o-ring that comes with the reservoir doesn't work.

So, after trying it with the new o-ring that came in the kit...it leaked.

After trying it with the original o-ring...it leaked.

Tried stacking o-rings...it leaks.

I went ahead and ordered $17 worth of custom size o-rings that would fit, but had a larger cross section. Well, I could get it to not leak just sitting there. But then when I let the engine run...its fukking leaks STILL.

I have literally tried 6 or so different sizes of o-rings, and have gone through nearly a gallon and a half of fluid trying to get this thing to seal.

It would normally be visible coming out the front side (where the fluid can gather), down the reservoir and leak off the bottom. Well it's not coming out the front side, but its still leaking.

I've spent over a week now trying to get the damn thing to seal, as I don't want to sell a vehicle with a leaking power steering setup (even if the leak is small).

I've replaced the return hose, and added worm style hose clamps instead of the crappy oem clamps.

I've also tried two of these dorman reservoirs, still have both with me...no dice on sealing.

I'm coming to the point of doing/trying the following:
1.) Get some oil dye and try and see EXACTLY where it is coming from.
2.) Just buy a reman'd pump and reservoir and pray they seal...but that seems to be hit or miss.
3.) Slather some Permatex Right Stuff RTX on the o-ring and around it to get it to farking seal!

I would damn near have this Jeep ready for sale if it weren't for this damn power steering leak.

All this because I accidentally dropped the foil from a fluid bottle in the reservoir.

 

[Digger87xj]

double o-ring and ultra gray silicone works for me.
+

 

[freerider15]

double o-ring and ultra gray silicone works for me.
+

Trying two smaller o-rings and some RTV might be what I try next...

 

[thejeepgod]

I have a stock pump w/ reservoir if you want to go that route...

 

[freerider15]

I have a stock pump w/ reservoir if you want to go that route...

Thanks Nick, but I *think* I have it nixed.

Tried an o-ring with lots of Permatex Right Stuff...still leaked.

So I finally gave up and went and bought a Durlast pump w/reservoir from Autozone.

Leaked after about 10 minutes of running.

So returned that one and picked one up from Advance Auto...turn out it's the same brand :laugh:

However, this one had a slightly different reservoir :dunno:

I was really really cautious this time around (did it kind of like I did my full hydro system). I jacked the front up and cycled the wheel back and forth at least 20 times to each side, allowing about 10 seconds in between. From there, I pulled the ignition coil plug and cranked it for a few seconds. This would get the fluid nice and bubbly (lots and lots of micro bubbles). Kept doing this until there were next to no bubbles to be seen, then plugged the coil back in and let her run. So far *crossing fingers* no leaks. I'll let it run more this afternoon and see if I see anything.

So much pain...for such a little thing.

I've spent $40 in power steering fluid at this point.

 

[ColoradoRaptor]

I feel your pain! Went through similar issues with my hydro assist set up....... I think I spent nearly 40 in fluid as well...:gee:

 

[freerider15]

I feel your pain! Went through similar issues with my hydro assist set up....... I think I spent nearly 40 in fluid as well...:gee:

Yeah it gets to the point to where it would be worth paying the $ for a better one.

If this were going to stay my Jeep, I'd look to do something like a PSC pump with remote reservoir. That way an inline cooler could easily be plumbed in as well.

So far the pump appears to be leak free. Haven't gotten around to driving it yet, just letting it run in the driveway. It's still showing some sort of leak, but I couldn't tell it that was new leak, or just old leak slowly leaking down. I went ahead and took the front skid back off so I can easily see upwards into there.

As of running it yesterday and letting it sit, there were still no leaks showing on the cardboard this morning.

I'll get the other things finished up, get an emissions test done, and drive it around some to make sure everything is 100%.

A lot of frickin' work for a vehicle I'm selling. Just can't bring myself to sell a vehicle that isn't 100%.