Ford Excursion :: Power Steering Box Leaking Suddenly


Jul 19, 2017

'03 Ex. 6.0 Diesel 160k miles.

I have a power steering box leak that came on suddenly. The leak is coming from around the pittman arm shaft... and it is pouring out. It's not under pressure, it's just running out and running down the pittman arm.

I've never seen a steering box leak as bad as this is. I've checked the hoses and they all appear dry. Is this common? Can the seal be changed in the truck or should I be looking at changing the steering box?

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About 3-4 months back replaced both PS lines and the leak stopped - briefly (maybe a couple a weeks).

Now the leak is back, but what's interesting is I lose more ATF fluid on a single long haul run than I do running round town for 3 weeks. I can't work out where the leak is coming from to identify what else to replace - short of just buying a pump and reservoir and replacing them as I've already done the hoses.

My turbo cooler pipe was hard up against the old PS pipe where it entered the side of the reservoir until I did the replacement hoses. Now I have it out the way but I'm wondering if it's caused some unseen wear or damage.

If I just do the pump to see if that works are the reman units any good out of Autozone or O'reilly's?

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1) The pump - I've read on this forum that the best way to go on brand of the pump is Motorcraft.

2) Hoses - I'd like to replace the hoses coming out of the pump while I have this thing all taken apart, but I'm not exactly sure what parts to get. I know one is the pressure and one is the return, but there are variations of each based on the research I've done. The parts on the Napa site have different descriptions like "with switch port", "without switch port" "56in hose" "26in hose", and so on. Which ones I need, specifically the ones connecting directly to the pump? I havent been able to find anything in my research online, in Haynes, or Chiltons manuals.

3) Washers - Whether or not I replace the hoses, should I replace the washers at the connection point? Chilton's seems to recommend replacing them. Will they come with the new pump?

My local auto parts shop has the pulley remover/installer for me to rent so I've already got that squared away. I'm pretty sure I've covered all of my bases otherwise.

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Any history of high pressure power steering line leaks at such low mileage/age before? Does 3 hours labor sound about right?

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There was no puddle underneath the car. The serpentine belt was tensioned. I drove the car to the Toyota dealer and presented the problem to a front desk technician. At first he said it could be the power steering pump or rack and pinion steering assembly. When I told him that the power steering was back after she made the return he said he'd never heard of that situation. Further, he said unless the problem was showing itself when we brought the vehicle in a repairman wouldn't be able to diagnose the situation.

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Question: The leak occurred while driving home from vacation today. Went we stopped for gas, we noticed a shutter in the steering. I added about a 1/2 quart to the reservoir - there was still some fluid but foamy. I made it home, and I when I checked again the reservoir was empty.

Should I go ahead and replace the pump while I am at it? I wondering it if could have gotten damaged from low fluid. The truck has 190k so it's not like the pump owes me anything. Will it make any of the repair easier to toss out the pump too?

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Since it's electric power steering I'm not sure what could have gone wrong here... and while it doesn't make the car un-driveable, it is rather annoying. The tire pressure is still around 37 PSI (according to the sensors) and they're Michelin.

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A word of caution of to any 7.3 owner. If you have over 200K miles and dont know if the power steering hose has been changed, CHANGE IT!!!. Its a $30 part.

Mine failed while I was towing a 9000 lb boat. I am very lucky that it happened where it did. I was going slow and just came out of a curve. It was a beast to wrestle off the road out of the way with no power steering or brakes. It felt like there was NO brakes at all. All the what ifs scared the crap out of me if it had failed at a greater speed or curvy section of road.

I had inspected the hose in the past and the rubber looked good with no marks or gouges. The 90 degree fitting coming out of the pump failed!

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So I replaced my steering gear box 10k miles ago and now my power steering is whining like a dying cat... I fill the fluid up and a week later it's back at it whining again... I was looking at the psc motorsports steering assist kit... you send them your gear and they rebuild and modify it to a hydronic ram assist setup. Should I just go with a redhead gear? Any other setup to cure our steering woes?I have an 2003 7.3 excursion....

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