Just finished completely replacing the power steering system in my 03 D2. New pump. New gearbox. New lines (all three). Tank was cleaned and reused. All new fluid. Now ... almost no power assisted steering. Its an absolute struggle to move the wheel when the truck is sitting still. There is flow in the tank, but not as much as there used to be. I have bled the darn thing for hours and hours, with a clear hose running from the bleed screw to the tank. Have never seen a single bubble. I've detached the drag link from the pitman arm and the steering is free from any binding. Likewise you can move the wheels without much effort.

All I can come up with is that I've either got a pinched or clogged line, somewhere, or the new pump is not moving enough fluid.

Suggestions?

 

What was the reason for replacing all of these parts? What were the symptoms beforehand?

Brian.

 

Good question:
The D2s Power Steering Pump blew-out and lost all fluid on my driveway, one evening. I replaced the pump, but apparently some debris traveled through the system from the first pump failing. I began to have a very dangerous "binding" in the steering when attempting to recover from a left-hand turn. I replaced all the ball joints and drag link and lower steering shaft, but could not get rid of the binding. Finally I gave-in and replaced the gear-box (and all hoses). The binding was eliminated. HOWEVER ... now I have very little power steering.

Its dark now but I did just read that incorrectly-routing your belt could result in inadequate pump pressure, but I find it hard to believe I did that. It looked like it could only go one way. Sure would make sense, though.

Open to other theories.

 

Seems like it would be difficult to get the belt on wrong.

Without ACE.



With ACE.



I hope you didn't get some leftover debris in the pump, before you swapped out the gearbox and hoses.

Brian.

 

Damaged pump? I've also chased that down. Replaced the second pump with a third new (rebuilt) pump last weekend. The low power issue remains exactly the same.

 

I'm assuming the PS hoses can only go on one way, no way of mixing them up?

 

Nope. No way to mix up the hoses. For as bizarre as these machines can be, the steering system appears to be idiot-proof. With the exception of this idiot.

 

There is a non serviceable filter in the reservoir?
......

 

I put a new tank in it six months ago. Drained it last week. Rinsed it out. Let it dry. No impact on the low-pressure/lack of assisted steering.