[s-cars] Losing hydraulic oil from power steering pump

[Charlie Smith]

Earlier, Tim Leonard wrote:
> 
> The X plug can be removed with a large
> 1/2" drive straight blade screwdriver available from Sears and others
> including NAPA. The tool I bought is from NAPA and the part # NS91 is
> stamped on it. I put it to the grinder to knock off the corners for a
> perfect fit. An impact wrench with you pushing with sufficient pressure
> works well for removal of the plug. The o-ring on the plug is especially
> hard and common o-rings will not hold the pressure. I have 6 on order
> currently but none "in stock". I have misplaced the part# for the o-ring. I
> was guessing anyway. We shall see if I guessed correctly when I receive
> whatever I ordered. The part # for a plug with o-ring is 026 145 541. You
> can order this from Crescent City Motors 800.966.7222 ask for the parts
> department they will send it to you.

Tim's correct on the O ring.  I'd recommend ordering the plug with the
new O ring, it's only about $12.  Obviously an error on Audi's part.
The new plug won't have the chisel marks that are on your old one  :-)

Here's a writeup on hydraulic fluid and with the part numbers for
the wrench and plug needed.

    http://www.elektro.com/~audi/hydraulic/

The wrench is really a drag link socket, which is like a stubby, wide, 
screwdriver. Go to a NAPA auto parts store and ask for a 11/16 inch, 
3/8 drive drag link socket. You may need to touch the outer corners 
to a grindstone, to narrow it maybe 1/16", otherwise it fits like a charm. 

When you go to NAPA, and the guy behind the counter looks like he is 
going to search catalogs for hours, it's NAPA part # NB-95. 

Go to Sears and get one of their Impact Drivers.  


Before you start, do this!  With the engine off, pump the brake pedal
30 to 40 times until the pedal gets very stiff.  You are doing this to
release residual hydraulic pressure in the system before you remove 
the X plug.  Now, using the Impact Driver and NAPA drag link socket 
you put the socket's blade in the X slot, and hit it smartly with a 
hammer.  Usually 2 or 3 smacks with the impact driver set to Loosen, 
not Tighten, and it will unscrew finger loose.  Use spray brake disk 
cleaner to clean the top of the pump and all around the X plug before 
you start.  You don't want any old O ring debris getting into the 
pump, and you want the outside of the pump nice and dry so you can 
see it's not leaking any more when you get done.  Lightly lube the 
new O ring with hydraulic fluid and when it's screwed back in finger 
tight, give it a few whacks the the impact driver and drag link socket 
and you're done.

    - Charlie


  Charlie Smith   charlie at elektro.cmhnet.org  614-471-1418  
  http://www.elektro.com/~charlie      Columbus Ohio   USA
  http://www.elektro.com/~audi     photos & technical info

  95 S6 Quattro  -  24 PSI, RS2 6 speed, and other features  
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