I'm in the process of trying to bleed/purge my new power steering system. I have the resevoir filled to the cold mark, cap off, wheels off the ground. As I turn the wheel lock to lock, the fluid rises and spills out of the resevoir filler. I've even tried it with the cap on and the pressure is enough to force the fluid out underneath the cap. I don'tthnk that i have it overfilled. I did noticed that the point at which it overflows is always in the samespot. Very close to when I approach full lock turning the wheel to the right. Can any one tell me if this is normal and walk me through the process of getting this bled. I really need to get my car back on the road!!
Thanks,
GReg

I did the turn left-right method and it worked very well but it doesn't seem to be working for you.
I'd just fill the reservoir, start the engine, and shut it right off again, refill and repeat until the level does not drop. Once you have the engine running with stable fluid level, then start the engine and turn it lock to lock then shut off and check level again.

The two main things are:

1, Don't run the pump with fluid level way low, the fluid will foam.
2. Don't hold the steering wheel at full lock with the engine running, it causes the full pump volume to be bypassed internally and promotes heating and foaming, especially during the filling proccess.

When air circulates through the power steering circuit along with the fluid, it enters the pump and the air/oil mixture is immediately whipped to a froth. Foam takes up much more space than just fluid. That is why you are seeing the fluid level rise and overflow the reservoir fill neck.

It is best to try and work as much air out of your system BEFORE starting your engine. With the wheels off the ground, you can steer lock to lock about 20 times. Refill with fluid as needed. Let it sit and turn lock to lock another 10 times. Now refill and start your engine. Air in the system should be minimal. Recheck the fluid level and go for a 10 mile drive. At worst you might have to let your car sit overnight so that any final small amount of air can rise to into the reservoir.

it was my understanding that before you start the motor, do as JIML82 suggested, but then remove the coil wire and crank the engine over to help clear out more air....I think you definitely have a foaming issue

The fluid does not seem foamy at all... but perhaps there are bubbles in the system that are causing the fluid to spill out. It only seems to happen if I turn the wheel too quickly. Otherwise the level does not seem to rise. So far I've probably go lock to lock with the wheels off the ground about 100 times. Still, if I turn the wheel to quickly it will overflow.

I contacted some retired Saginaw Steering Gear engineers. It sounds as if you have an air leak somewhere in the system. It is possible to have a leak on the low pressure side of the system that can actually allow air to leak in and yet not leak oil out. (Air molecules are much smaller than oil molecules.)

The return line from the steering gear back to the reservoir is one possible location. Make sure that the connection of the hose to the reservoir spout is correct. Is the hose inserted all the way? Is the clamp tight?

The connection of the return hose pipe to the gear port. Is it torqued correclty? Are you sure that the pipe didn't have a crack on the flare end? Can you see a complete round contact pattern on the brass seat inside the gear port?

Do you have a remote reservoir? Are the connections of the hose at the reservoir and at the pump secure? Is the large spout on the pump secure? You might try and smear some light grease or petroleum jelly around the joint of the pipe to the pump. This should seal for a short time and give you an indication as to the source of the problem.

Also, if you have a remote reservoir, is it a General Motors reservoir? Or do you have an aftermarket one? Some of the aftermarket reservoirs are notorious for recirculating air and not giving the fluid enough time to expel the air.

The seal on the input shaft of the gear can also be a source of an air leak. You might try and smear some petroleum jelly or light grease around the shaft and seal. This also is just a short term fix but again may give you a clue as to the source.

Lastly, the driveshaft seal on the pump can also be a source of an air leak. Usually the pulley covers that area so it is difficult to see and or try and apply grease to the seal.

Hope these actions may give you some clues. Please let us know what you find.

JIML82

Jim,
Thanks for the suggestions. I am using a stock remanufactured 68 pump and a remanufactured 3rd gen gear box. Using the lee adapters in the gear box. I'll try some of your suggestions and report back.

I have not heard of anyone having any problems with the Lee Manufacturing inserts. But make sure that you have installed the inserts squarely in the ports (particularly the lower pressure port nearest the input shaft). Look to see that you have a nice round indentation in the face of the insert. That indentation would indicate that your pipe is seated well and is sealing properly.

Greg,
Here are a couple more ideas from the retirees.
Is there any chance that your parts (pump, hoses, steering gear) could have been laying around to a point where they could have collected a small amount of water inside? It only takes a teaspoon of water in the power steering system to cause all kinds of noise and foaming. Water is quite difficult to get out of the system.

Is there any chance that someone tried to rap on the end of the pump driveshaft? (For instance, trying to break the pulley loose from the driveshaft.) A sharp blow on the end of the driveshaft can break a plate inside the pump. The pump will still flow oil, but the crack in the plate will cause all kinds of noise and airation.

Good luck,
Jim

I don't think that water could have gotten in there.. These are brand new parts right out of the box. I put the pulley on myself and did not hammer the pump at all.

i've always just topped the resevoir and started the engine. the level will immediatey go down a lot, so i will refill. once the level stays up, i will then move the wheel slowly from lock to lock until the level stays good and it quits making noise. it has always worked for me, and i've only ever made a couple of messes. plus, it's all done in about 5 minutes.

Novaderrik,
I took your advice. I topped off the resevoir and fired her up. No leaks whatsoever. Thanks for the help. Once question though, the steering feels a little too overboosted. I was expecting a bit more feel to it since its the 3rd gen box. Is there a way to solve that problem? Is there a different flow valve i can use?

You need a box from an IROC, or Trans Am that comes with 16" wheels. Those boxes have the most feel. A regular Z/28 with 15" wheels has one step softer feel, a non high-perf third gen probably is softer yet.
David