Update cont.
We put the hood back on and I lifted the front end off the ground to cycle the steering for bleeding. It just didn't seem to get that light feeling I was looking for but I decided to drive it around the block to see if that would help. Well, no pressure from the pump not only means strong arm steering but knee popping manual brakes since I run hydroboost. I went slow but while trying to come to a stop the engine would over power my foot hydraulics even when idling! I threw it in neutral and got it to stop. Around the block didn't bleed any air so I parked it for the night and resorted to taking the car to work for another week. My sweet

has been without a car for several weeks and doesn't even complain about. She's just sad for me to be faced with a mystery problem to figure out.
Since I did the rebuild I couldn't rule out a mess up so that meant pulling it off. I drained it and it got a little messy. The bottom bolt now has limited access due to proximity to the frame and the steering gear box also limiting wrench travel. I bought a racheting wrench (can't get a socket in there) and found it too was too thick to get into the spot it needs to get. An open end wrench is pretty much it but a normal sized open end was too long to get any travel before it would hit the frame or the engine. I resorted to sacrificing an open end by turning it into a stubby and with that I was able to get the range of motion needed to loosen that bolt. Alright... two nights after work killed and I finally get the pump off the engine. I look inside for missing seals, wrong turned vanes, or backward parts but nothing is out of place. So a wipe down and back in it goes, fill it up, try and bleed it and no pressure.
Continued research and figured the thing I modified was the pressure relief assembly. Enlisted the help of someone smarter than I and figured the mods I made are not working together. I drilled the flow nut and increased pressure by removing a shim in the pressure relief piston. He suggested increasing pressure further because my flow size was too big and it wasn't building pressure so we determined a thickness and I went to the hardware store to see what I could find. Basically by increasing the tension on the spring you are increasing the amount of pressure the pump sees before the seal is broken to bleed pressure. A power steering pump is designed this way so that you get good assist/pressure at low rpm and then at higher rpm when the pump is spinning and producing lots more pressure the relief valve bleeds it off so it doesn't hurt the system. Anyways here's the washer I found. This time I could leave the pump mounted and just remove the pressure assembly.
WARNING!! (ADDED 5/2010): The following arrangement caused pressure bleed too early which resulted in a no to low pressure result. DO NOT follow this assembly. Please refer to
IH8MUD.com - View Single Post - Family haulin' for the correct washer placement.
This is where I put the washer. It is a 3mm washer at .018" thickness that I shaved to .016". That's what he determined and I trust him.
I put this in, hooked up the hose, and filled it back up. I started bleeding it and checking my fluid level. Then all of the sudden I had feather light steering. I'd press the brakes and if I press hard enough I can get it to load the engine and drop some rpms so I knew I was now getting PRESSURE! I dropped it on the ground and the assist made it easy to turn the wheel. I then had my

come out and cycle the steering on the ground while I checked out the linkage. She turned passenger and I told her to hold it there, then we heard a weird sound, it was 1-2 second long and started like a fluid strain and got loud like a belt squeal. Then it was over and she said the wheel got heavy so I told her to turn it off. I looked for leaks, checked my connections and looked at the fluid. Nothing seemed out of order so I started the engine again and there was no pressure.
I drained it AGAIN and took out the pressure relief piston. The end had a bunch of material on it, not metal but fibrous. This is the intake for the pressure relief and as the pressure in the pump builds up it goes through here to push against the ball seal and once the pressure overcomes the spring tension it'll bleed the pressure. So I cleaned the screen off, put it back in, filled up the reservoir, crossed my fingers that it was that simple and started the engine.... no pressure.
Called up my friend to pick his brain and while I was waiting for a call back I figured since I'd become a pro at it I might as well take the pump off. So I drained the fluid (I really should just put a drain plug on this thing!), removed the hoses, dripped ATF everywhere and got out my stubby wrench for the bottom bolt. Oh and I have to take one of the engine mount bolts out to get a better angle on that bottom bolt too. As I took the pump off something did not seem right. The pump did not come out like this, like it should.
It came out like this.
Well, I better open it up to see what happened. There is a clip that holds the vane head onto that shaft so maybe that came off. I got it open and found my problem, I had sheared the pump shaft!!!
I've never heard of this happening but here it was. These are strong pumps with good parts so I wasn't sure how the shaft would have been weak like that. I got my call back and told him what I found and then we put it together. Due to the blockage on the intake screen to the pressure relief valve there was no pressure being bled. When I had my

keep the wheel turned this build an incredible amount of pressure that couldn't be bled and with a gear driven pump powered by diesel low end torque the pressure built up so much that it stopped the vane head from spinning and it was no match for the reciprocating mass of the diesel components so something had to give and I was fortunate that it was only the shaft that sheared. According to guess calculations we figured the mods gave me around 1700psi max before bleeding. He figured the pump head saw 5-8x's that amount causing a fluid lock! So these are strong pumps. And what caused that fibrous blockage on the intake screen? ME

. I wiped down the pump with a rag that left lint everywhere, consequently hard to see when wet, and when that lint lifted and flowed with the fluid it got caught on the screen and keep fluid from entering the pressure relief valve. Boom.
At that time Brokenparts had called back and we found one of his pumps had the same shaft size and would work (I needed a 3/4" shaft diameter). We were in the area on tuesday so he left the pump out and I picked it up. I especially like his choice of hose plug.
I opened it up and its vane head and thrust plate weren't in good condition so I mixed and matched parts to make the best pump. I didn't reuse my body because of the metal chips that got into my shaft bushing but I reused all of my internals and seals minus the sheared shaft. I also cleaned differently with a final spray of parts cleaner and an air dry from compressed air. Lesson learned.

came out to check on me and found me deep into it. In my defense, sometimes you just have to get into the right position.
With the pump back together, bolted up and hoses attached I filled it and started up the engine to prime. Guess what... no pressure.
I was beyond crying or laughing, I was just numb. Maybe this pump doesn't like my modded pressure assembly. I drained the fluid, cleaned up the stock pressure assembly that came with this pump and put it in. Hooked up hose and filled with fluid... no pressure. You know even with all this selling it never ever crossed my mind. I know it's something simple and with a good nights rest and some more thought I have another plan.
There were some drips I saw later coming from the canned ham housing and when I put it back on the pump I remember thinking that the housing seal looked a little funny but I went ahead and put it back in the truck. After another call and some thought the pump may be pulling in air when spinning thus cavitating causing it not to prime. It was too late to do anything about it before starting work the next day so Dora sits another week with an engine just waiting to be broken in. I think I'm all caught up now.