Paying for new and getting reconditioned is complete crap. Both of mine were new AFAIK - had the green dot and were sold as new by the dealer.
Maybe the pristine gear will be the answer.
bootfoot
Please continue with the saga. I'm having the exact same problem. Two psp's, knocking in each. Both were new Toyota parts, installed by dealer. I've gotta do the proper system bleeding technique this weekend. My thought process has been just like yours as to eliminating possible causes, but...
Thanks for posting this, especially the pics w/ part nos. Had my PSP replaced at Thanksgiving. Only 2 parts are on the invoice:
44320-60182, described as PUMP ASSY, VANE L, and an unspecified amount of PS fluid. Nothing for O-rings or gaskets. Could there be more than one version of that...
Ditto on the Beowulf thanks. I've got a tick/knock that started after a psp replacement. Had a whining, too, but that turned out to be a pulley (seems to be just to provide tension?) and can be easily replaced.
I missed this thread when looking for psp knock issues.
bootfoot