Power Steering failing - PS fluid bubbling out

[TazzmanianDevil94]

Have a problem that is reoccurring in relation to the power steering. Twice now in as many months the power steering has failed, when I have popped the bonnet the Red Cap is still in place but the power steering fluid is all over the top of the power steering fluid container. The cap is not cracked, nor the container. Any ideas what could be the cause and cure. Last time it occurred was back in March this year and after 300 miles it’s happened again.

[Scott560]

The cap isn't air/liquid tight.

I suspect that means the fluid is either being over pumped (there is a pressure regulation valve built into the pump body, maybe it is stuck closed), or perhaps there is a leak in your PS hoses somewhere. Overnight the fluid leaks out and air seeps in, and then on startup the pump violently forces the air back into the reservoir and sprays it all over the place.

It's not something that's been reported on here before as far as I can remember. I have had leaking PAS cooler pipes before, but that only ever made the fluid go down and the pump run dry and sound bad.

I'm sure you aren't overfilling it but good to confirm. the max level is about 2 inches from the top?

[Vtecmec]

It could also be a blockage in the system, I'd be checking the rubber hoses and the cooler too.

[TazzmanianDevil94]

If it is the cooler that has the issue, not bringing the temperature down, can anyone message me where I can get an aftermarket one or a replacement cooler. Thx

[Scott560]

I doubt it will be a temperature issue. I bypassed mine with 8 inches of rubber pipe and 2 hose clamps on my early 5th gen, and did track days, no bubbling over.

There is no OEM replacement available - you will have to fashion something yourself or bypass it (Probably not such an issue in the UK as our summers are so short lived!).

If you don't have much time to diagnose, whipping the pump off and replacing probably isn't very expensive or much work at all. Had a quick check on Amayama , looks like most of the important internal gubbins aren't available, but most of the seals are:

https://www.amayama.com/en/genuine-cata ... ne/E__1900

Is the fluid frothing?

[Andyjess666]

You can get a cooler off eBay it's not a direct fit but with a bit of fiddling you can it to fit an pumps are easy to swap

[TazzmanianDevil94]

The first time she failed I replaced the pump, 300 miles later and she has failed again, when I popped the bonnet the power steering fluid was just on the top of the power steering reservoir. So either a temperature issue or maybe air getting in.

[wurlycorner]

There is no OEM replacement available - you will have to fashion something yourself or bypass it (Probably not such an issue in the UK as our summers are so short lived!).

As Scott says - nothing available that's direct fit.
I spent a year looking round and eventually found a Ford Transit oil cooler that has basically exactly the same dimension and style pipework/loop, but made out of aluminium. The brackets are completely different though and I had to fashion some up to match the existing mounting holes on the chassis, to the cooler.
When I get a moment I intend to do a write-up on the forum in case of use to others.

The cooler is there for a reason, so it should be replaced rather than bypassed long term - but I agree with others that short-term, looping it out with rubber hose doesn't cause the problem you're seeing (I had to loop it out for a while).

Can you drop a thermometer in the reservoir after it's been used and gone high-level, then we can get that compared with a 'known good' 4th gen on here?

If it's air getting in, then I would have thought the fluid would look slightly frothy - does it?