forum.audiv8.com Foren English Audi V8 Forum Power Steering pump rebuild// My first V8

Due the pump needs to be completely dismantled for that, it is strongly recommended to refurbish the pump completely.

Leave the front bracket fitted to the pump housing. So you can clamp it in a vice safely.

1st. Screw out the eight cylinder cover caps one after another. You possibly will need some force (hammer and chisel) to undo the caps. Then remove the springs, rods and pistons out of each pump cylinder. Store the parts in order of their removal. Check the threats inside the pump housing for cracks and damages. If there will occur any trace of mechanical damage at the threats or O-Ring seats you may quit now and bin the pump.

2nd. Remove the two bolts (6 mm Allen key) from the rear end of the pump and separate the pump housing from the oil reservoir. Mind the washer at the shaft end.
3rd. Remove the slide ring and the bushing from the shaft
4th. Press the shaft out of the pulley flange (a power press or solid vice is required).
CAUTION: There is a mark on the shaft tip that shows the position of the counterweight fitted to the flange. Mind that later when you reassemble the pump.
Mind the second washer at the shaft, that mostly gets stuck inside the pump housing. The two shaft washers must not be switched when you reassemble the pump.
5th. Remove the relief valve from the oil reservoir (7 mm Allen key). It is located in the middle of the reservoir. Dismantle the valve carefully. It contains 4 balls washers and a spring. Small parts may get lost! Clean all parts seriously. When reassembling, the larger ball belongs to centre and the three smaller ones onto the larger one.

Now replace the oil ring of the pump housing

Put the shaft back into its housing (mind the washer) and press the flange onto the shaft. It is mostly important to clean the shaft tip from grease and oil before fitting the flange back to the shaft. Mind the mark and the counterweight.

Fit the bushing and slide ring to the shaft (oil all parts, the new O-Rings as well, with hydraulic fluid before replacing). Fit the rear washer to the shaft. Fit the six small O-Rings to the pump housing. Fit one large O-Ring to the oil reservoir and fit the reservoir to the pump housing.

Warm up the eight O-rings of the cylinder covers in 80°C hydraulic fluid before fitting them to the caps. Grease the O-ring seats inside the pump housing sparingly. Replace all parts in correct order.

Good luck.