Sometimes; things just don't go right. Power steering reservoir leak.

[JDNobodi]

Working on my Dodge Cummins and installed the PSC remote reservoir kit.
Poured a quart and a half fluid in and have it leak on the ground.

Turns out there was a gap between the pump body and reservoir housing - right at the bottom.

Turns out one the bolts hole on the back of housing didn't line up. When the bolts where installed, it forced the reservoir down therefore causing the gap. I found this out after I hammered on the reservoir for a half hour trying to close the gap.

I slotted the hole with dremel tool assemble the pump and reservoir again and pressure tested it.

Removing and installing the power steering pump is a PIA on a Dodge Cummins.

 

[JDNobodi]

Well, apparently 20 psi is not enough to test for leaks because as soon as installed the pump on the truck put fluid in it, it leaked. I think when I tighten the bolts on back of pump after I mounted it, I disturbed the canister. On top of that, I couldn't get it pump fluid.
******* **** it. On top of all that, I strained my left shoulder doing the job. I didn't feel like embracing the suck when I'm hurting.
I figure I either have
A) bad parts
Or
B) I'm a dumb ass

So I waited till today to work on the truck even though I'm not 100 percent. This time before pulled off the canister, I pressure tested and ducked the pump in a bucket of water. Yep it's leaked around front like last time. I pulled the canister off and noticed I installed the pressure relief valve wrong and in the wrong order. The pump was basically pumping fluid back into itself.
Okay now to figure why it is leaking around the front. I pulled off the o-ring off the pump and the new o-ring out its package that came with the canister. Well there is a difference. The o-ring that I was supposed to use is thicker. I didn't use it because the one that came with the pump was new too. I didn't realize the o-rings were different. I installed the correct o-ring and correctly install the pressure relief vavle.
I pressure tested it at 50 psi in a bucket of water and no leaks.
I reinstalled the pump again and finally no leaks and it pumps fuild. So to answer my earlier question, the answer is B) I'm a dumb ass.

 

[livid4dirt]

I remember when i bought mine, the instructions had a diagram for all the o-ring placement and sizes. Without that it would have been trial and error for me.

 

[Fordum]

Sadly with me, I never feel I even have the "A" option........Its always "B"......

 

[JDNobodi]

Sadly with me, I never feel I even have the "A" option........Its always "B"......

What sucks we know better and the answer is at the back of our minds nagging us that we screwed up. Then we have to pull it all apart hoping we didn't mess something else up.