My Truck is a 97 dodge CTD 2500 4x4 5 spd extended cab. I have encountered a problem that will probably cost me a small fortune.
A few days ago a substantial oil leak developed. At first inspection I thought that the problem was the infamous seal between vac pump and the power steering pump.
Upon closer inspection I noticed that the power steering pump reservoir was overflowing with engine oil and that this was the source of the problem. Somehow the pressurized oil from the vac pump had made its way past the front seal of the power steering pump into the power steering pump reservoir and subsequently pumped throughout the entire power steering system.
This, as you guessed, has probably caused major damage to all power steering components as well as the hydro-booster for the brakes that contain seals which are incompatible with engine oil.
Upon disassembly, the problem was evident. One of the tabs on the vac pump coupling has sheared off, and subsequently the metal fragments have invaded the sealed bearing in the steering pump allowing the oil to be pressurized into the power steering system.
A rough cost for this fix is $600 for the hydro brake booster, $350 for the steering pump, $500 for the power steering box, $150 for new lines and $1100 for the vac pump. All prices are Canadian.
I have not factored in the cost for the labour.
Please also drop a post to let me know if you have heard of this happening before. The only suggestion I could present is to carefully check the condition of the coupling ears if you ever change the seal in the coupling. If substantial wear has occured on the coupling, the front power steering seal may need to be serviced. I really hope this will not happen to anyone else.

 

Maybe I'm missing something here, but isn't it pretty much impossible for that to occur (oil getting into pwr str)? There is an open space in between the vac pump and the pwr steer pump. I think you are confronting two different probs here. As far as the pwr str being overfull, I can't think of any possible way engine oil could enter this system without going in through the fill cap. On the contamination end of it (booster, lines, HVAC vac motors) I have seen that occur, as matter of fact there is a tsb conserning this on some earlier years (I'll try to research a number on this).

 

Thanks for your reply.
Everyone I have discussed this with has said exactly what you have mentioned that it is impossible for this to happen.
Once I show them the parts they quickly see how this has happened. There is no air gap between the Vac pump and the power steering. There is a seal between each unit and the entire sealed bearing face on the power steering pump is subject to pressurized oil if the seal fails inside the coupler. If for some reason the power steering sealed bearing has failed as well as the coupling seal then the oil has a direct path into the reservoir.
I thought as you did that the oil must be coming from a failed check valve on the vac pump, which is the TSB you are mentioning, but this is not the case. All vac lines are dry.

 

Why would engine oil necessarly take out all the hydraulic system, its just heavier oil and the pressure is regulated. Drain and flush it all good and put synthetic in it. Should be ok.

 

NO, don't you believe for one minute this can't happen. It did to me last week.

It was on the wifes truck.When oil gets past the seal it invades the PS pump, and like you say, into the system. I got the the vacumm pump at employee cost. $710, I replaced the drive lugs on the PS pump but that didn't work so a new PS pump. The new drive lugs has to be presses exactly at the correct depth, or it won't seal with the vacumm pump.The brake system has been flushed out and there seems not to be any damage there. Labor? Prolly bout $500.

Yes it can happen. It has before and it will again.

..Preston..

 

Thanks for the insight on that one. I'm more familiar with the 98.5 up trucks and the design on those vac/pwr str is separate. If you have an oil leak at the vac seal, it goes on the ground. I'll have to check that out when one of the old school trucks comes in the shop.

 

Thanks guys for the interest.
I am new to this as well. So far I have been really lucky. I asked around for some advice and one guy had a complete Vac and Powersteering unit for $200 that was removed from a newer engine because it was to be intalled in a generator.
As far as the rest of the system I have flushed it out very well and will try synthetic. Hope it all works! My fingers are so tightly crossed...it's difficult to type.

 

$200. You better cross the fingers. After I got the bill from Dodge for another vacumm pump,PS pump, seals and labor I owed $2100 more. And Monday the Co. I worked for decieded I was to old to work the field any more. So at 60 I'm gonna change professions.

..Preston..

 

Well it appears that all the finger crossing has worked.
The $200 vac pump and steering pump unit is working. All went well with the installation. I drained and flushed all the compnents very well, put all new lines on, and presto.....so far so good.
If anyone has any questions feel free to contact me and I'll do my best to fill you in.
Thanks to all who sent me advice and encouragement.
Thanks DTR

 

thom how can a company say you are to old to work the feild if you are doing the job.