Steering gear rebuild - FAIL

[Daveo91Burb]

Over last fall/winter I rebuilt a steering gear from my ‘90 parts rig that I had years ago. It was challenging for sure but I followed a YouTube vid from a guy that seemed like he knew what he was doing and when I put it together everything seemed to fit into place properly and function seemed good on the bench. Over the last week I finally got the thing installed in my burb. I bled the system the only way I know how: got the wheels off the ground and kept adding fluid and turning steering wheel lock to lock slowly. I thought I was mostly there and then took it on a mile test drive. Pump was pretty noisy and when I got back I knew I had more bleeding to do. But this time I didn’t get front wheels off the ground. Added some more fluid and turned wheel lock to lock on smooth shop floor. Something happened in one of the cycles (pressure surge?) and the output shaft seal blew out and fluid gushed out.

I’m giving up on the rebuilt box, have a reman on order that should be here today. Just need to know if there was something I did wrong in the bleeding - definitely don’t want same thing to happen to my new box. Is there a better way to bleed these P/S systems?

 

[yevgenievich]

Seal not seated all the way with snap ring? I would put the reman box in the bench and go through adjustment procedure before putting it in if it is a standard parts store reman

 

[Daveo91Burb]

Seal not seated all the way with snap ring? I would put the reman box in the bench and go through adjustment procedure before putting it in if it is a standard parts store reman

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Yep, exactly what happened. I think I know why now too. I put the wrong snap ring in when I rebuilt. I had two Edelman rebuild kits, basic and deluxe. I used everything from deluxe but for some reason I broke open the basic one and used a few parts out of it. Perhaps I mixed up the snap rings. The new one is a much tighter fit. I took the output shaft out, reseated both seals and washers, installed with new snap ring. I think it’s going to be worth the time risk for me to try install the one I rebuilt again. If it’s good I can save $175, assuming autozone let’s me return without a restocking fee (I used free ship to home)

any tips for bleeding these systems? Or anything I could have done wrong to cause a pressure surge?

 

[yevgenievich]

If I remember correctly, first should turn back and forth with engine not running. But generally never had issues with just running and turning the wheels following by a short trip. Back when I first bought a reman from autozone, it blew out on the first long trip and killed the power steering pump. I checked the second one my self before putting it in

 

[Daveo91Burb]

If I remember correctly, first should turn back and forth with engine not running. But generally never had issues with just running and turning the wheels following by a short trip. Back when I first bought a reman from autozone, it blew out on the first long trip and killed the power steering pump. I checked the second one my self before putting it in

Got the rebuilt (not reman) box back in. No leaks, but still can't seem to get it bled properly. I turned it lock to lock a bunch of times, engine off and wheels raised before I started it. Still getting pump whine, foamy fluid, and a hiss out the reservoir cap when I shut off the engine. I thought I was close and took it for a drive, but definitely still air in the system - felt like no power steering at all at low speed. Hopefully I didn't screw up the pump?

Going to try again tomorrow. I read one thing online that GM said up to 40 lock to lock turns (engine off, wheels raised) if you have a P/S cooler. I also saw something about using a vacuum pump and modifying a reservoir cap with a nipple for it.

If anyone has any good tips for bleeding these systems, I'm all ears.

 

[yevgenievich]

Did the power steering work before the seal blew out? Would venture maybe the pump having an issue if it worked before the seal popped. Or top it off with fluid and just go on a longer drive to see if it settles.

 

[Daveo91Burb]

Did the power steering work before the seal blew out? Would venture maybe the pump having an issue if it worked before the seal popped. Or top it off with fluid and just go on a longer drive to see if it settles.

Got it working. I think letting it sit overnight helped. Today got the fluid level right, got wheels off ground, turned lock to lock 25 times with engine off. Checked fluid and it was foamy, but let it sit for 15 minutes and then turned lock to lock a few more times and it was clear. Took it for a drive and ran great, no pump whine, good feel at the wheel.

Only problem now is wheel is off center when going straight. Probably about 15-20 degrees to the left. I can't remember if I've ever gotten it aligned since I've had it but it's probably due. Or should I just take the wheel off and reposition?

 

[yevgenievich]

...
Only problem now is wheel is off center when going straight. Probably about 15-20 degrees to the left. I can't remember if I've ever gotten it aligned since I've had it but it's probably due. Or should I just take the wheel off and reposition?

On 4wd just adjust the link between the pitman arm and the thing on the knuckle to center the steering wheel.

 

[Daveo91Burb]

On 4wd just adjust the link between the pitman arm and the thing on the knuckle to center the steering wheel.

Cool thanks. While I was doing this project I was thinking I couldn't mess with that adjustment since it would change steering geometry, but after thinking about it, you're right - won't change relationship between two wheels at all. I may still get an alignment, but might not need one right away.

 

[PrairieDrifter]

Update? Did it last?

 

[Daveo91Burb]

Update? Did it last?

I think so. I haven't driven it much over the summer since I've been doing a pretty major update to the tune (upgraded to a later model PCM). Doesn't seem to be leaking at the box at least. But.....

Now I'm leaking bad at the pump. I thought it was the pressure hose, but I replaced that and still leaking from that area. I'm trying to decide if should just replace the pump or buy a unit with the reservoir included? Does anyone know if the reservoirs themselves go bad, or is it usually just the pump that leaks?

 

[PrairieDrifter]

I think so. I haven't driven it much over the summer since I've been doing a pretty major update to the tune (upgraded to a later model PCM). Doesn't seem to be leaking at the box at least. But.....

Now I'm leaking bad at the pump. I thought it was the pressure hose, but I replaced that and still leaking from that area. I'm trying to decide if should just replace the pump or buy a unit with the reservoir included? Does anyone know if the reservoirs themselves go bad, or is it usually just the pump that leaks?

The pumps usually just leak.

I do have a question though. I was trying to do my input shaft seal, didn't think it would be that crazy, which it wasn't. I just didn't research hardly at all, watched a few short videos, not the right ones lol. I was slightly unlucky also as the stub shaft twisted out with the adjuster piece.

I was unaware I had to hold down the stub shaft while undoing the adjuster, to just replace the input seals. So the stub shaft, valve body, and worm gear all came spinning out. Anyways I had an issue during reassembly and I know I didn't line up the dowel pin on the stub shaft and spool valve, problem #1. So it's not fully seated where it should be.

I can't wrap my head around how the worm gear and ball bearings contact and in general. Problem #2

So my question is, did the ball bearings fall out into the bottom of the box and now I have to rebuild? lol

 

[RawkerStatus]

I think so. I haven't driven it much over the summer since I've been doing a pretty major update to the tune (upgraded to a later model PCM). Doesn't seem to be leaking at the box at least. But.....

Now I'm leaking bad at the pump. I thought it was the pressure hose, but I replaced that and still leaking from that area. I'm trying to decide if should just replace the pump or buy a unit with the reservoir included? Does anyone know if the reservoirs themselves go bad, or is it usually just the pump that leaks?

My pump started leaking at the shaft seal, bearings went out on it after driving 100 or so miles after it blew the sector shaft seal from a bad remaned gear box. i got the steering pump with the reservoir, figure im already messing with changing out the pulley why bother with one more thing.

 

[yevgenievich]

I think so. I haven't driven it much over the summer since I've been doing a pretty major update to the tune (upgraded to a later model PCM). Doesn't seem to be leaking at the box at least. But.....

Now I'm leaking bad at the pump. I thought it was the pressure hose, but I replaced that and still leaking from that area. I'm trying to decide if should just replace the pump or buy a unit with the reservoir included? Does anyone know if the reservoirs themselves go bad, or is it usually just the pump that leaks?

I have jb welded seams on some reservoirs if was suspecting them leaking before. Did not have leaks after rebuild

 

[Daveo91Burb]

The pumps usually just leak.

I do have a question though. I was trying to do my input shaft seal, didn't think it would be that crazy, which it wasn't. I just didn't research hardly at all, watched a few short videos, not the right ones lol. I was slightly unlucky also as the stub shaft twisted out with the adjuster piece.

I was unaware I had to hold down the stub shaft while undoing the adjuster, to just replace the input seals. So the stub shaft, valve body, and worm gear all came spinning out. Anyways I had an issue during reassembly and I know I didn't line up the dowel pin on the stub shaft and spool valve, problem #1. So it's not fully seated where it should be.

I can't wrap my head around how the worm gear and ball bearings contact and in general. Problem #2

So my question is, did the ball bearings fall out into the bottom of the box and now I have to rebuild? lol

Hmmm, it took me a couple of tries to get the balls correct. I turned the worm too far once or twice and lost a few in the case - start over. If there's any doubt that you don't have all the balls in the worm or recirculating tube I'd probably want to take it all apart to be sure. I had no idea how those balls work until I took it apart and saw how they operate.

I'd start with this video - this guy's style entertained me, but it seems like most of his advice and methods are pretty good. Worked well for me. It's a time investment to watch, this is only part 1, but I don't think you could condense the rebuild of a saginaw box down to five minutes and have it be worth anything.