1988 Mazda B2600 Power Steering Pump and PS Line Rebuild

[goodfellow]

I seem to be doing a lot of PS pumps lately. Had to replace one on the family truckster a few weeks ago, and now the old Mazda needs a pump as well. My problem is that the truck is so old and rare (these days) that they are no longer available. I searched Rock Auto and they will only do a rebuild if you send them the old pump -- they have no remanned parts on the shelf.  ---- "Ain't nobody got time for that!!"

The noise in the pump was definitely a bearing. So I took a chance and removed the pump to see if the local parts store would have a bearing in stock. It was a good bet. The local NAPA matched me up a bearing for $20. I probably could have saved a few bucks if I went on ebay and matched it, but then I'd have to wait.

Before starting, I put a plug over the valve assembly bore to ensure that parts didn't drop out (this is a complex valve system with many small parts and check balls) -- so I just plugged it up to ensure the parts stay put.



The pulley was stuck tight after all these years, and it needed a lot of heat and some Kroil to get loose.....



... while the bracket bolts also needed some heat



Everything finally came apart ..



There is a snap ring in the top to hold in the bearing, and once it's removed, a quick blow with a brass hammer from the back released the assembly.







The shaft popped out and the bearing was definitely rough.



Everything apart and ready for cleaning and reassembly.



The bearing is easily driven off the shaft with a brass hammer





The new bearing was pressed on the shaft using a socket to drive it on the shaft and the old seal and spacer were reused for installation back into the housing.



A socket was used to drive it home and reinstall the retainer clip.



Everything was reinstalled and the shaft was tight --



Good to go!

[goodfellow]

Put everything back on the truck and went for a drive .....and promptly lost my power steering. The trek was a lot of fun and we went through several muddy trails and creeks just having a good time. The truck was working well, but it did get a few dings and dents along the rocker line. No problem though -- it's a beater old truck with a home brew paint job, and I'm not worried about it.



I started having PS problems toward the end of the run and I noticed increased noise. Long story short I got it home expecting to R&R the PS pump again, but after further inspection it turned out to be a corroded PS line.



The PS lines are rubber sleeved at two points across the front cross member, and under those sleeves rust and corrosion eat away at the lines. This line has a pinhole leak.





To make matter worse, while taking off the 10mm bracket bolt, my 10mm SK 1/4" drive socket bit the dust.



The line was toast so I cut it with a body saw and split it to add a piece of high pressure hose. It's a Rube Goldberg fix, but you just can't get these lines anymore from a local supplier. They are very hard to come by and until a find a new set, the high pressure hose fix will have to do.





I eliminated the rusted holding brackets and spliced in a piece of 5/16" hydraulic hose. It will do until I can track down a set of new lines for this old warhorse.



I refilled and bled the system and it works pretty well. At least this way I can go back out on the trail over the coming holiday weekend.