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I've recently noticed a small leak on the ground after my truck has set overnight. To start with, I have a 1999 with 230k on it. I had the front end completely rebuilt last year due to issues with Toe-in, ball joints, and bearings. $3,000 worth of work done. One of the main reasons for the work, was due to the Steering locking up while turning at slow speeds, and there being a lot of play in the steering, plus the truck having 230k on it with no front end work prior to last year. I've read throughout the Site, where some folks have had the same issue with their steering. After I had the front end rebuilt, my steering "locking up" went away, but I still have a lot of "play" in the Steering Wheel. The problem I think I have now is more of a seal leak on the gear box, I think. I've read where the pump builds up pressure while the steering is locking up. I think I'd waited too long to have the front end work done, thus causing the seals on the gear box to leak. I started noticing it after I had the work done on the front end. Now it’s getting worse. Yesterday while driving home, I could hear a whining noise while turning and braking. I've check the level of fluid and its okay. I went down to the carwash and cleaned off the gear box this morning. My question is: Could I have waited too and caused the seal on the top of the gear box to leak? If so, can that seal be replaced, or do I have to buy a new gear box. I'm leaning towards buy a new gear box (thinking that would fix the play issue too). I’m just looking for options before spending any more money. I've tried to post pictures of the gear box, but can't seem to get them on this post. There are four bolts that are on top of the box. It appears fluid is leaking around the seem on the top of the box.
You can buy a complete seal kit for less than $10 for the leak. I would adjust the meshload on the box before you make any further decisions. A lot of the time, that's all it takes to tighten up all the slop. Do a search in this forum and there is plenty of info on it. If that doesn't tighten it up for you enough, then buy a new box. No sense in buying a new box if adjusting it will fix the problem.
As far as the typical Ford power steering noise, many are using synthetic fluid and are happy with the results. They say it really quiets them down. I've owned Ford's for so many years, I don't know what I'd do with a quiet steering pump.