Had a look through the forums and got some info on this.

Initially had indications of a leak under the wheel arch on the drivers side.

About 3-4 months back replaced both PS lines and the leak stopped - briefly (maybe a couple a weeks).

Now the leak is back, but what's interesting is I lose more ATF fluid on a single long haul run than I do running round town for 3 weeks. I can't work out where the leak is coming from to identify what else to replace - short of just buying a pump and reservoir and replacing them as I've already done the hoses.

My turbo cooler pipe was hard up against the old PS pipe where it entered the side of the reservoir until I did the replacement hoses. Now I have it out the way but I'm wondering if it's caused some unseen wear or damage.

Any thoughts??? Oh and if I just do the pump to see if that works are the reman units any good out of Autozone or O'reilly's?

 

When it was leaking before, was it leaking from a screw on joint, hose crimp or another location in the plumbing?

Did you check all of the joints/unions of the entire system? The fluid has to be coming from somewhere. Don't forget that it is a hydro-boost system, so the PS system might be OK and the leak may be up higher near the fuse panel.

What about soaking everything with Simple Green and a good rinse and then drive it while keeping an eye on it?

Pictures of where the leak it running down from or to at all? Sometimes that can help others that have had similar problems recall their experiences.

 

The leak this time is as non descript as before. Just seems to be ATF everywhere on the hoses and pump and drop in level on the reservoir. I will do a clean up again and post some before and after pictures - good advice thank you - i should have realised I didnt give much to go on

 

From Underneath



Pump from underneath



Wheelarch



Top pipes



Reservoir Connections



HP PS hose connection



Steering box??



Bottom of reservoir

 

The foregoing pics are before the clean up, I assume.

I suggest cleaning everything up thoroughly, filling the reservoir to the correct level, and making no other change for a while. Just monitor once or twice a week for the development of red wet spots. What gets wet first will help pin point a problem, if you still have one.

One possibility is that you may not. You recently had your front axle worked on. Not once, but twice, the second time for the shop to repair the mistake they made during the first time. The point is, whenever the front axle or ball joints are being worked on, from time to time it becomes necessary to swing the steering linkage to the left or right in order get it out of the way or position the knuckle bores in line to remove and replace the internal axles.

Whenever the steering linkage and gear are moved without the truck running, the Ford CII pump pukes steering fluid all over the driver's frame rail and steering gear. The fluid squirts out of the breather hole in the power steering reservoir cap. I noticed that your breather hole was quite clean, compared to the muck covering the rest of the cap. The relative cleanliness of the tiny breather orfice suggests that it was recently used as a squirt nozzle. Fluid can squirt all the way up to the hood liner insulation, when the steering is moved without the pump turning.

I know this to be true from personal observation... while manually manipulating the steering linkage from under the truck, and, from involuntarily having to drive the truck home without a serpentine belt. It was the latter experience that taught me just how far the fluid can fire out of that little hole. I have an oil spot on my hood insulation just above the fuse box.

So, the oil mess that you are witnessing may or may not have had anything to do with your long trip... depending on the timing of when you actually looked for the mess, and the time that work was last done with or on your axle. Not necessarily a diagnosis here... but just another possibility of causes for you to consider.

 

Cap????????

 

Yep pre clean up, i'll try and do clean up tomorrow - weather permitting!

 

I hope Y2KW57 has nailed it! Be sure when cleaning that you put a plastic bag over the reservoir cap to keep water/detergents out of the fluid.

Let us know how it goes.

 

So confession time

I just said screw it and bought a refurbished pump and installed. I should have cleaned up first to be sure but I'm occasionally a bit like that.

New pump is in, steering and brakes seem way better. Plus the leak appears to be gone - fingers crossed!

I followed the guides on the forum for changing the pump.

Tip: went to Ford and bought two white plastic o rings extra - just in case ($4.50). Still have them if someone needs one.
Tip: Pump came with a white plastic o ring and a small black one - I have the Gates hose and the black o ring is not required - did throw me for about 45 mins tho.
Tip: Immersed said white o rings in boiling water to expand it some and make it more malleable for sliding over threads - also put plumber tape on threads after putting o ring on to ensure no leaks

Keeping old pump as apparently there is a gates kit to refurbish #350450

Used pulley pulling and pressing kit on loan from Oreilly's. Pulley was a bit crooked at the start with the press but just kept lining it up with light rubber mallet taps until it squared up on its own and went on lovely.

 

Don't overfill the reservoir or it will puke out the extra in a hard turn.

Expect it to whine for a while until the air is out of system.