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Power Steering Pump Rebuild
 
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Pelican Technical Article:

Power Steering Pump Rebuild

Steve Vernon

Time:

2 hours2 hrs

Tab:

$25

Talent:

***

Tools:

13mm, 2 small flathead screwdrivers

Applicable Models:

Porsche 944 Turbo (1986-89)

Parts Required:

Power steering pump rebuild kit, power steering fluid

Hot Tip:

Be prepared for fluid to spill out

Performance Gain:

Proper steering

Complementary Modification:

Oil and filter change

The power steering pumps on the Porsche 944s are known to leak oil and leak a lot of oil. If your pump doesn't leak now it will in the future. A lot of people just keep topping up the fluid until they have fully coated the front of the engine with dirty power steering fluid. If your pump is starting to leak don't just keep adding fluid. With Rennbay's power steering pump rebuild kit you can seal the kit and get it back in shape in a couple of hours. The kit comes complete with everything you need to rebuild your pump with the exception of the power steering fluid.

You will need to remove the pump from the vehicle to rebuild it, so please see our article on power steering pump replacement for instructions on how to safely remove the pump.

If your power steering pump is starting to leak don't just keep adding fluid.
Figure 1

If your power steering pump is starting to leak don't just keep adding fluid. Remove the pump (red arrow) and rebuild it with the Rennbay power steering pump kit.
 

The kit comes complete with everything you need to rebuild your pump with the exception of the power steering fluid.
Figure 2

The kit comes complete with everything you need to rebuild your pump with the exception of the power steering fluid. The kit is also used on several other vehicles and pumps so you will not use all of the pieces in the kit. Just follow the instructions and do not worry when you have pieces left over.

With the pump removed from the vehicle give it a good cleaning.
Figure 3

With the pump removed from the vehicle give it a good cleaning. You are going to open the pump up, and you do not want any dirt or debris getting in.

Use a marker and mark across the case halves and the mounting bracket (red arrows) so you can easily line everything back up when putting it back together.
Figure 4

Use a marker and mark across the case halves and the mounting bracket (red arrows) so you can easily line everything back up when putting it back together.

Use a 13mm wrench and remove the four bolts taking note of the difference in them (red arrows).
Figure 5

Use a 13mm wrench and remove the four bolts taking note of the difference in them (red arrows).

Put the pump down face first on the pulley (yellow arrow) and lift the back of the pump off (red arrow).
Figure 6

Put the pump down face first on the pulley (yellow arrow) and lift the back of the pump off (red arrow).

Remove the large gasket from the base and replace it with the appropriate gasket from the kit (red arrow).
Figure 7

Remove the large gasket from the base and replace it with the appropriate gasket from the kit (red arrow).

Remove the two-piece gasket (red arrow) from the plate inside the pulley section of the pump (yellow arrow).
Figure 8

Remove the two-piece gasket (red arrow) from the plate inside the pulley section of the pump (yellow arrow).

Take the two replacement gaskets from the kit and place the soft rubber gasket inside the plastic outer gasket.
Figure 9

Take the two replacement gaskets from the kit and place the soft rubber gasket inside the plastic outer gasket. You can install this now or wait until you are reassembling everything later.

Use a flathead screwdriver and gently pry the plate off the pump (red arrow).
Figure 10

Use a flathead screwdriver and gently pry the plate off the pump (red arrow).

Remove the plate and then the circlip on the pump shaft (red arrow).
Figure 11

Remove the plate and then the circlip on the pump shaft (red arrow). Use care when removing this clip so you do not lose it; there is not a replacement clip in the kit so make sure it does not go flying off in your garage.

Lift the pump (red arrow) off the pulley shaft but do NOT invert the pump or the vanes in the pump will fall out.
Figure 12

Lift the pump (red arrow) off the pulley shaft but do NOT invert the pump or the vanes in the pump will fall out.

Place the palm of your hand firmly over the base of the pump to keep everything together.
Figure 13

Place the palm of your hand firmly over the base of the pump to keep everything together. Then turn the pump over. While securely holding the pump in place (red arrow) in the housing, remove the seal from the shaft opening (yellow arrow). You can just use a flathead screwdriver and pry the seal out.

Clean the seal area well.
Figure 14

Clean the seal area well.

Install the new seal with the flat side facing out (red arrow).
Figure 15

Install the new seal with the flat side facing out (red arrow).

Push or tap the new seal in place.
Figure 16

Push or tap the new seal in place. I like to turn the housing back over and push the seal in by pushing down on a socket to seat the seal (red arrow). Installation is the reverse of removal. Place the housing down over the shaft, insert the circlip, install the plate with the new two-part gasket, install the base with a new O-ring and bolt everything back together.

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Comments and Suggestions:
Mark Comments: Thanks....I did that about ten times. There is nothing that limits how far the shaft drops in except for the seal. It can drop in all the way to the housing if the seal does not stick out. Plus I measured your seal and the original.......yours is narrower.
April 23, 2016
  Followup from the Pelican Staff: Then I would contact our part specialists. Maybe the wrong part got to you.

Give our parts specialists a call at 1-888-280-7799. They can figure out what part or repair kit you need.
- Nick at Pelican Parts
 
Mark Comments: I used this kit but when I put my pulley in and reassembled the pump the pulley seized. The new wiper seal sits lower in the housing causing the pump to bind up against the pump body
April 19, 2016
  Followup from the Pelican Staff: I would disassmble the pump and check that something wasn't installed out of order, or left out. The shaft may be dropping in too far. - Nick at Pelican Parts  

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