Fill Process

This procedure is recommended whenever the power steering pump (3A674) , steering gear (3504) or hydro (if equipped), is removed, serviced and installed into the power steering hydraulic system.

Materials Required

1. A vacuum pump with gauge, capable of pulling 84 kPa (24 in-Hg). The vacuum source should be one of the following:
   • Distributor Test Machine Vacuum Pump
   • Vacuum Motor From An Air Conditioning Charging System.

2. A No. 7 stopper cap, or a special power steering pump cap assembly with a tee connection, shutoff valves and a power steering pump auxiliary reservoir (3E764) . The devac tool can be used.

Preparation

1. Assemble the vacuum fill system.

2. Install the vacuum fill system on the vehicle. If the steering gear or power steering pump has been changed or flushed, allow old fluid to drain from the system.

3. Tighten all steering system and vacuum fill connections.

Initial Fill

1. Install the cap on the power steering pump fill neck or rubber stopper on power steering oil reservoir (3A697) .

2. Open valve No. 1 and allow the power steering fluid to bleed through the tee fitting. Close valve No. 1 after bleeding.

3. Pour enough steering fluid in the power steering pump auxiliary reservoir to exceed the amount required for filling the system.

4. Close all valves.

5. Open valves No. 2 and No. 3. Start the vacuum pump. Operate the pump until a gauge reading of 84-101 kPa (25-30 in-Hg) is obtained.

6. Close valve No. 3, and shut off the vacuum pump. Watch the gauge for approximately 30 seconds. If the vacuum reading drops more than 3 kPa (1 in-Hg), there is a leak in the power steering or filling system that must be corrected.

7. Start the vacuum pump. Open valve No. 3. Operate the pump until a gauge reading of 84-101 kPa (25-30 in-Hg) is obtained.

8. Close valve No. 2, and shut off the pump. Open valve No. 1 to fill the steering system with fluid. The power steering pump auxiliary reservoir should be elevated higher than the power steering pump and power steering oil reservoir .

9. When fluid stops draining from power steering pump auxiliary reservoir , close valve No. 1 and remove cap or rubber stopper.

Final Fill

1. Adjust fluid level in power steering oil reservoir to correct level. There will be a slight drop in the level when the engine is first started and the steering wheel (3600) cycled.

2. Operate the engine at an idle for 15 minutes, then inspect for leaks. It will not be necessary to devac the system unless there is evidence of air in the power steering pump that could cause noise or affect performance.