mkriete

My PS return line and rear seal of my PS pump had been seeping since I purchased my shark (1980 US A/T). It was time to replace the line and seals. However, not everything went per plan. This post is a supplement to great directions reference below. I hope that I can save someone hours of frustration.
I followed the great these how-to’s:

Dwayne’s PS return Line replacement: https://rennlist.com/forums/928-foru...with-pics.html

Sharkskin’s Round 26: http://members.rennlist.com/sharkski...26-PS-Pump.htm

And of course, I also followed the WSM. I found removal enjoyable. Everything came apart rather easily. The extra space was a great chance to clean up the engine bay as well.

Then came the PS pump rebuild. I removed the pulley, the rear plat, and hit a brick wall. It took several good swings at the shaft to drive it out, and it would not move. So I got a wooden block to protect the threads, and hit it harder. It still did not budge. So I put it in a press and loaded the shaft as much as I was comfortable (it was a 60 ton press). The shaft still did not move. I stopped several times along the way to research the pump further. The pump is an early ZF pump. It looks like the right pump. The specifications match. The rear seals match the kit.

SURPRISE! The front oil seal does not match the pump (yeah, I should have looked at this first). I put the WSM to the side and removed the front seal. Low and behold I find a snap ring on the front side of the shaft. I remove the snap ring and now I can finally drive out the shaft. Of course, I had already dropped out all the vanes. I carefully examined the bearings and I could not find any damage. I put the pump back together and hit the auto parts stores to find an oil seal (20x42x6). I really got tired of telling the salesman that the make and model of my car did not matter, I had the dimension of the oil seal, and then waiting for the guy who had some idea what I was talking about. I learned that the seal I needed does exist, but no one could get it. I hit the European car specialists; same story. I had someone refer me to an industrial equipment supplier in town. Bingo! He had the seal I needed in stock (20x42x7) and confirmed it would work in the heat of a PS pump.

So far, so good. The PS pump is working and is quiet. The best I can figure is the pump was rebuilt and the bore enlarged, requiring new bearings and oil seal.
If the oils seal does not match, you may have the same condition.