I used this thread when I rebuilt mine but it’s been a while. Not 100% sure if 1g and 2g are the same.

https://www.dsmtuners.com/threads/how-to-rebuild-and-modify-a-power-steering-pump.345914/

I bought a new pump. Only thing I'm having trouble with is that single o-ring. It won't snap in properly and seal. I was wondering if anyone had any tricks or tips on how to do this?

So you’re having issues putting the hard line onto the yellow circled, correct?

tk106 said:

So you’re having issues putting the hard line onto the yellow circled, correct?

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No. This one:




It is for the hose that goes straight from the reservoir to the pump.

If you're still not understanding I can send a pic of it at like 9:30 tonight.

Weird because if it’s that tight and still leaking when you get it on, something isn’t right.

tk106 said:

Weird because if it’s that tight and still leaking when you get it on, something isn’t right.

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The problem is that the o-ring breaks everytime I put it in, or it won't go all the way in (crooked)

BLACK'98DSM said:

The problem is that the o-ring breaks everytime I put it in

Click to expand...

But you were able to get it in by twisting and it still leaked? Is that right?

tk106 said:

But you were able to get it in by twisting and it still leaked? Is that right?

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Yes, but I pulled it back out to inspect and the o-ring was broken. I'm having trouble putting it in, it is super tight and the best I have done without breaking it is putting it in crooked.

Try a smaller o ring

tk106 said:

Try a smaller o ring

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Ok, that's a good idea.
I used the one included with the new pump, then I tried an A/C one. I guess I'll run to Lowe's and look in the plumbing section for a smaller one.

Guess the pump is different for 420a

tk106 said:

Guess the pump is different for 420a

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It would appear that is so.

When I rebuilt my pump, I ordered a gates kit and the two top o rings were too big. I had ac oring laying around and those fit and hasn’t leaked in about a year

Same inner diameter and smaller outer oring

I would just re-use the one from the old pump since it didn't leak or break but like an idiot I said "oh its old" and threw it in the trash

Haha. I’ve done that too. Now you won’t throw anything out until the job is done and road tested

The pressure should be low on that hose, so perhaps if all else fails try gasket maker? Not a good permanent solution but gets it running perhaps. It shouldn't be that hard to make this work, and the o-ring does sound too big and is pooching out and getting pinched off as you tighten. You should be placing in on the tubing, and seating it into the recess, not the other way round (at least, that's how these are arranged on a 1g pump like mine.) I took the return fitting off my pump and put it back on with the old ring, and no problems yet (now I've jinxed it!, damn.) As far as getting the right o-ring, look in the factory parts catalog or an online one like Amayama.com, and see if they call out the I.D. in mm. I was able to do this for an o-ring on my new rack for my car. It came with two O-rings of the same size, but he pressure (supply) is only supposed to be 6mm, while the return is 7.5mm. They had one at my local NAPA. I had looked at a company that lists many rebuild kits on ebay called power steering seals, so perhaps they can get you the right size. send a photo of the sealing parts.

tk106 said:

So you’re having issues putting the hard line onto the yellow circled, correct?

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This is the pressure side, and there are rings at the top and bottom of the banjo ftng. The return is the one he's indicating.