PS Pump rebuild

PeterBergin at PeterBergin at
Mon May 9 20:09:17 EDT 2005

Well, did the job today, was pretty straight forward with the normal amount 
of bloody knuckles.  Using everyone's suggestions, the Bentley and a link on 
Chris's site, I ended up replacing all the o-rings in the pump, caps and hoses.  
It was never obvious which one was leaking, other than it was on the bottom 
of the pump.  The rings under the caps were brittle along with the ones on the 
check valves.  The ones in the body looked pretty good. I figured that the 
worst part of the job was getting the pump out of the car, so the rest was worth 
doing without having to go back in again.

However the only part of the job that produced any profanity was when I 
attempted to pull off the pulley mount with a gear puller and promptly broke off 
one of the ends, so now I only have two bolts (with red locktite) holding the 
pulley on.  I called a buddy who runs an Audi repair shop and he informed me 
that what I did was a pretty common DIYS screw up, and he assured me that there 
are a lot of Audis running around with only two bolts holding on that pulley.

Moral of the story, don't mess with the shaft seal without the right tools!

Thanks for everyone's help.


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