2004 D2 Steering Fluid Leak - pump or box? or...
Hi guys, my Disco is bleeding steering fluid... started slow but now it's undriveable as the fluid practically goes right through it. I've ruined my driveway and the street. I have been using Dex/Merc transmission fluid in the PAS reservoir at the recommendation of my mechanic - he said that's what they use. When this first started there was clearly a leak at the coupling shown on the left hand side of the attached picture. When turning the wheel that nut was literally spraying fluid. I cranked it tight (it was loose) and the leak stopped for a while but now it's tight and the system is leaking more than ever.
How can I tell what component is broken? Is it the pump, or the steering box? or some other part? What type of diagnostic things can I do to try and find out? Does a fault here show up on a meter so if I found someone who has a code reader we could get info that way? What are your thoughts about DIY replacement of the pump or box once we find out what this is?
You guys will LOL but I have my once a year vacation at the end of month and already paid almost $500 to take the car on the ferry to Nantucket as driving on the beaches and picnicking there is always a highlight of our trip. Now it looks like we'll be wheelin' in the minivan :-(
Edit: noise... the noise that you get at full lock (or at low PAS fluid) that noise was happening in neutral steering position, i.e., going straight
Any help would be very much appreciated!

How can I tell what component is broken? Is it the pump, or the steering box? or some other part? What type of diagnostic things can I do to try and find out? Does a fault here show up on a meter so if I found someone who has a code reader we could get info that way? What are your thoughts about DIY replacement of the pump or box once we find out what this is?
You guys will LOL but I have my once a year vacation at the end of month and already paid almost $500 to take the car on the ferry to Nantucket as driving on the beaches and picnicking there is always a highlight of our trip. Now it looks like we'll be wheelin' in the minivan :-(
Edit: noise... the noise that you get at full lock (or at low PAS fluid) that noise was happening in neutral steering position, i.e., going straight
Any help would be very much appreciated!

Last edited by sickdisco; Jul 9, 2013 at 10:18 PM. Reason: fixed picture
I would spray it with engine cleaner and your garden hose to make it clean.
Then figure out exactly where it is leaking.
If the leak is seals - you can put a cap full of brake fluid in to expand the seals.
Worked like magic on my Discovery I.
Then figure out exactly where it is leaking.
If the leak is seals - you can put a cap full of brake fluid in to expand the seals.
Worked like magic on my Discovery I.
I dont know what this washer looking thing is and why it's bent? Is that normal? After cleaning and observing leak if I determine it's coming out here should I tighten this nut, induce brake fluid or Lucas stop leak? Both?
I'm very new to Discos, and not even sure if an '04 is set up the same....but I'll chime in with what I just did to mine.
When you look at your reservoir, look below it and there are two metal lines, that go down to the steering box with an oval shaped metal washer that clamps down on both of them. Mine was bent a little becasue the previous owner installed a crappy aftermartket line. It would spray out of there everytime I turned my wheel. Turned out to be a relativley easy/cheap fix with a new line and rebending the washer.
However, the delaer told the old owner it was the power steering pump and quoted him $1,200.
When you look at your reservoir, look below it and there are two metal lines, that go down to the steering box with an oval shaped metal washer that clamps down on both of them. Mine was bent a little becasue the previous owner installed a crappy aftermartket line. It would spray out of there everytime I turned my wheel. Turned out to be a relativley easy/cheap fix with a new line and rebending the washer.
However, the delaer told the old owner it was the power steering pump and quoted him $1,200.
based on your responses I went and checked everything again after cleaning and drying the components... since the reservoir was emptying w/o the car running I ruled out the requirement that the fault be correlated with operating the system. So I focused on what things could be involved with the system "off" and carefully dried then observed this hose to pump junction. Sure enough, before my very eyes, this sumbitch started dripping again! Right onto my shirt I might add!! So there's probably other things wrong with it but if I can figure out how to replace this hose/clamp I might have a shot at fighting another day
First, your mechanic is a dam idiot, you do not rune ATF in a D1, only p/s fluid, D1's did use ATF.
You need to power scrub the top and bottom of your engine, then while it is running crawl under and have some one crank the wheel back and forth, you will see the leak real quick.
You need to power scrub the top and bottom of your engine, then while it is running crawl under and have some one crank the wheel back and forth, you will see the leak real quick.
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