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Old 04-03-2012, 08:05 AM   #151
maxifire
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Quote:
Originally Posted by SubieMonte View Post
Hey maxifire.

I'm sourcing the parts to do the rebuild. Do you have any advice on reinstalling the orings so I don't pinch them? Thanks!
I was not the one who did the hands on but from observation, I would say you really need to make sure that the O-ring is seated horizontally flat down in place and cup the other end of the housing flat down to ensure that the O-ring doesn't fall out of position if you get what I mean.

I don't think it is all that difficult. Good luck!
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Old 04-03-2012, 01:24 PM   #152
SubieMonte
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Sweet thanks!
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Old 04-15-2012, 09:49 AM   #153
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Old 04-24-2012, 02:08 PM   #154
muakies
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Thanks for the detailed writeup and pictures. Appreciate it!
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Old 05-01-2012, 02:09 PM   #155
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Quote:
Originally Posted by ckswanecamp View Post
Sorry in advance if im being redundant. But that o-ring kit featured in the diagram from opposed forces is for the 02-03 pump. Just a friendly FYI (Possibly again)
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Old 05-01-2012, 09:48 PM   #156
wrxadamsti
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I have taken the chance and bought the 02 wrx rebuild kit for the pump in my 03 sti which is defferent to the 02. The high/low pressure o rings weren't the best fit so I'm assuming this is why it still loses power steer when on a hard fast corner, its fine all other times now.

This all started when i fitted my silicone turbo inlet pipe, undid the top bolt and line from the pump and once it got that bit of air into the system it lost most of the power steering and caused me to find this all out and rebuild the pump. So ill be looking for better fitting o rings to rebuild again soon.
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Old 05-01-2012, 10:14 PM   #157
SubieMonte
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Quote:
Originally Posted by wrxadamsti
I have taken the chance and bought the 02 wrx rebuild kit for the pump in my 03 sti which is defferent to the 02. The high/low pressure o rings weren't the best fit so I'm assuming this is why it still loses power steer when on a hard fast corner, its fine all other times now.

This all started when i fitted my silicone turbo inlet pipe, undid the top bolt and line from the pump and once it got that bit of air into the system it lost most of the power steering and caused me to find this all out and rebuild the pump. So ill be looking for better fitting o rings to rebuild again soon.
Did you replace the bearing and seal as well?
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Old 05-02-2012, 11:51 AM   #158
othon
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Okay to share my current experience so far (pre pump rebuild) this is the direction and list of item I am awaiting.

I went with PTFE, one because the overall properties for this brand appears to be the most robust all around and two having stock would come in handy if other issues or later rebuilds are necessary. Or I could share.


9559K173 PTFE O-Ring, AS568A Dash Number 136, Packs of 5 1Pack $9.69

9559K133 PTFE O-Ring, AS568A Dash Number 037, Packs of 5 1Pack $13.48

9559K18 PTFE O-Ring, AS568A Dash Number 013, Packs of 25 1Pack $7.28

9559K19 PTFE O-Ring, AS568A Dash Number 014, Packs of 25 1Pack $7.34

9559K21 PTFE O-Ring, AS568A Dash Number 015, Packs of 25 1Pack $7.37

9559K61 PTFE O-Ring, AS568A Dash Number 017, Packs of 25 1Pack $11.54

9559K115 PTFE O-Ring, AS568A Dash Number 021, Packs of 10 1Pack $5.59

6661K104 Precision-Plus Steel Ball Bearing --
ABEC-1, Double Sealed Bearing No. 6203 for 17 mm Shaft Diameter $10.08



For the shaft seal I decided to use the one supplied from [Rocket Seals] that OP suggested a while back.
So I will keep you all posted and share pics

Item Name: Metric Oil Seal 20mm-24mm Internal Diameter (20X32X8-MOS/D)
Quantity: 1 unit
Price: $3.95
Properties:
Shaft I.D. (Millimeter): 20
Bore O.D. (Millimeter): 32
W Width (Millimeter): 8
Lip Type: ADL
Material: NBR
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Old 05-02-2012, 10:12 PM   #159
othon
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Well got the PTFE rings and will be sending them back. They are very hard and might not compress well enough to allow the pumps sections to mate together properly.

Stay tuned...
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Old 05-18-2012, 02:52 PM   #160
othon
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So I ordered the FEP VitonŽ Fluoroelastomer O-rings. Installed them and...Not so much!

These rings may have some great stats but are not adequate for the rebuild.

I have ordered the same ones as the OP and will be doing it again. Side note the rebuild including pressing out the bearing and seal and replacing them isn't that bad.

Also I ordered the shaft seal from Rocket Seals matched to the OEM seal fairly well and pressed in great and was a great seal around the prop shaft for what I can tell with it all disassembled...
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Old 05-18-2012, 02:54 PM   #161
othon
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A little photo fun
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Old 05-20-2012, 01:59 PM   #162
NutBucket
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Tackled this job yesterday. Was very straightforward thanks to all the info in this thread. Thanks to everyone who contributed!

And yes, it was very easy to replace the bearing and shaft seal without a press.
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Old 05-21-2012, 04:12 PM   #163
68Cadillac
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Quote:
Originally Posted by othon View Post
I have ordered the same ones as the OP and will be doing it again. Side note the rebuild including pressing out the bearing and seal and replacing them isn't that bad.

Also I ordered the shaft seal from Rocket Seals matched to the OEM seal fairly well and pressed in great and was a great seal around the prop shaft for what I can tell with it all disassembled...
Thanks for testing all that out. Updated my master parts list as a result of your efforts. Thanks.
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Old 05-25-2012, 11:47 AM   #164
othon
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....well im at my whits end! Not sure what im missing but this is the third time and the back case half keeps leaking. ..."sigh"

The last time I used a newer used seal off of a 08+ pump which didn't seam to leak for me. But I wanted to put in the new seal (FEP encapsulated)...and it leaks.

I know torquing the back 4 bolts would help but at this rate with having to take everything apart and back then bleeding the system. I now need to weigh the time needed and spent, plus money spent in the DIY, compared to just getting a new pump and being done for another 7-8 years like the original lasted!
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Old 05-25-2012, 11:52 AM   #165
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OP < Would you mind sharing your torque spec you used on the back 4 bolts for your rebuild, for the people. Thanks.
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Old 05-29-2012, 02:00 AM   #166
68Cadillac
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Quote:
Originally Posted by othon View Post
OP < Would you mind sharing your torque spec you used on the back 4 bolts for your rebuild, for the people. Thanks.
I went to 12 lbfˇft at first like I do with all aluminum but fluid seemed to slip past the large o-ring at the back. So I upped it to 35 lbfˇft and that seemed to do the trick. YMMV.

Last edited by 68Cadillac; 06-08-2012 at 12:49 PM. Reason: torque units wrong. number unchanged.
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Old 06-06-2012, 07:15 PM   #167
yungsupark
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Default Saabaru owner thanks you and question ATF vs PS fluid

Thanks for this amazing write up, I've been dealing with the exact same issue with my '05 Saab 9-2 Aero. Near the end of last summer I had the same symptoms as you plus some of the PS fluid was dripping onto my exhaust manifold causing white smoke to plume out the hoodscoop. So I had my oem PS pump rebuilt back in October of 2011 (along with having the valve cover gaskets replaced which isn't cheap) and it was working fine until just a few days ago when I noticed my PS go on me while making a U-turn, got home checked my levels and was a the cold minimum level. Bad...saw the fluid collecting in the exact same area you show in your photographs, same as last time for me so frustrating that I have to deal w/this faulty PS pump again. But at least I've got a great roadmap thanks to your write up, although I'll probably just buy a rebuilt PS pump instead of trying to rebuild mine again on my own.
Question for you - my mech used PS fluid after reinstalling my rebuilt PS pump, but my manual and the PS reservoir cap says to use Dexron/ATF and I noticed you use ATF. Do you think using PS fluid caused my rebuilt PS pump to fail and should I stick with ATF when I fix it this time around?
Thanks!
kp
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Old 06-07-2012, 07:33 PM   #168
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You're welcome.

Quote:
Originally Posted by yungsupark View Post
Question for you - my mech used PS fluid after reinstalling my rebuilt PS pump, but my manual and the PS reservoir cap says to use Dexron/ATF and I noticed you use ATF. Do you think using PS fluid caused my rebuilt PS pump to fail and should I stick with ATF when I fix it this time around?
I use Dextron/ATF because that's what the manual instructs me to use. Could using "PS Fluid" cause your pump to fail? Probably not. I'd look to the previous rebuild for the cause instead of the fluid. It's just hydraulic fluid.

You should definitely only use Dexron/ATF this next time round. Even the Mobile1 upgraded stuff I use is not that expensive. Plus you know exactly what it is if it ever starts leaking, again. It's deep red and smells bad.
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Old 06-07-2012, 10:18 PM   #169
hoffmanEstates
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its not easybfinding a rebuilt p.s pump for an oh four I will say
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Old 06-11-2012, 01:12 PM   #170
todd_fuller
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Did anyone else have an issue with the spec'd FEP o-ring size for the sensor on the back? It was a real pain to get it on and then mine leaked once installed. Ended up replacing with a fatter Buna-N o-ring.
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Old 06-11-2012, 01:25 PM   #171
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Originally Posted by todd_fuller View Post
Did anyone else have an issue with the spec'd FEP o-ring size for the sensor on the back? It was a real pain to get it on and then mine leaked once installed.
I had a hard time getting that one on myself. Took my time getting it on and even warmed it up a bit to ease it on without damaging the ring.

Mine doesn't leak, but I did see how easy it would be to damage the FEP ring and get leaks.
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Old 06-12-2012, 09:30 AM   #172
othon
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Quote:
Originally Posted by 68Cadillac View Post
I had a hard time getting that one on myself. Took my time getting it on and even warmed it up a bit to ease it on without damaging the ring.

Mine doesn't leak, but I did see how easy it would be to damage the FEP ring and get leaks.
Yeah I didn't do that may self since the encapsulated ones are not all that compliant. I might get non encapsulated silicon rings next time.
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Old 06-19-2012, 03:18 PM   #173
othon
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Well. I cant take it any more...Im gonna do the Buna-N O-Ring for the large case half seal and toruqe it this time..
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Old 06-19-2012, 06:14 PM   #174
SubieMonte
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Quote:
Originally Posted by othon
Well. I cant take it any more...Im gonna do the Buna-N O-Ring for the large case half seal and toruqe it this time..
Sounds like finding a remanned one is the way to go?
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Old 06-25-2012, 10:43 AM   #175
todd_fuller
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So I just completed the rebuild and I don't see any leaks at this point. Some things I learned:

- Probably better to use buna-n for the sensor seal, FEP was too hard to get on and not leak.
- Back cover has a tiny step that you need to make sure the big o-ring is past otherwise you'll likely pinch the ring.
- prelube the rings with ATF before to install.
- I did *not* take off the coolant hose, instead I removed the alternator. This gave me more than enough room.
- Definitely get some hose to replace the lines that you have to move to get to the rear pump mounting bolt, these don't really seal up once you've disturbed them (also, when the alternator is out, there's really easy to get to.)
- Buy TWO of every seal, just in case you damage one. The car won't be down waiting for a new one to come in the mail.
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