The leak is coming from the seal on the steering rack. The leak is very bad when the steering is locked and the pressure is highest. No obvious signs of rust or damage to the steering rack. Here's what I've done so far:

-Replaced the seals from the hoses to the rack. Still leaks when the steering locks to either side.

-Replaced the steering rack with a salvaged rack (I know I know I took a chance on it). Leaks less but still leaks when the steering is locked.

What can I do next? Do I bite the bullet a get a reconditioned rack? Or am I missing something?

Sounds a bit too much of a coincidence to get two leaky racks.

I'd be checking for a blockage or kink in the return line.

And also considering pump over-pressurising.  Is it electro-hydraulic or full hydraulic?

Did you use the correct green fluid or the old red stuff?

My thoughts exactly about the rack!

Didn't seem to be any kinks but I could have a look again.

It's a full hydraulic pump.

If the pump is over-pressurising is it time for a full pump replacement?

And it's the old red stuff I'm afraid. Should get the green stuff but didn't want to buy only for it to end up on the ground.

Thanks for replying, been driving myself mad trying to figure it out!

22 hours ago, TomsFocus said:

Sounds a bit too much of a coincidence to get two leaky racks.

I'd be checking for a blockage or kink in the return line.

And also considering pump over-pressurising.  Is it electro-hydraulic or full hydraulic?

Did you use the correct green fluid or the old red stuff?

My thoughts exactly about the rack!

 

Didn't seem to be any kinks but I could have a look again.

 

It's a full hydraulic pump.

 

If the pump is over-pressurising is it time for a full pump replacement?

 

And it's the old red stuff I'm afraid. Should get the green stuff but didn't want to buy only for it to end up on the ground.

 

Thanks for replying, been driving myself mad trying to figure it out!

As it's the fully hydraulic system, there are no electronics controlling the pressure. 

There is a pressure switch on the pump but that just tells the ECU to raise the revs if you're dry steering at idle.

So if the pump is over-pressurising then I would assume it'll need replacement. 

I think there's a bypass valve inside the pump that may be clogged with dirt & debris but I don't know whether that's something that could be cleaned or replaced if you are confident with stripping the pump down.

If it was mine, I'd try changing the pump before going to the expense of a reconditioned rack.

On 1/29/2024 at 7:44 PM, TomsFocus said:

As it's the fully hydraulic system, there are no electronics controlling the pressure. 

There is a pressure switch on the pump but that just tells the ECU to raise the revs if you're dry steering at idle.

So if the pump is over-pressurising then I would assume it'll need replacement. 

I think there's a bypass valve inside the pump that may be clogged with dirt & debris but I don't know whether that's something that could be cleaned or replaced if you are confident with stripping the pump down.

If it was mine, I'd try changing the pump before going to the expense of a reconditioned rack.

It turns out it is an electro hydraulic pump. Is there a sensor controlling the pressure that I could replace? There's no error codes coming up for any issue with the power steering

12 minutes ago, df1989 said:

It turns out it is an electro hydraulic pump. Is there a sensor controlling the pressure that I could replace? There's no error codes coming up for any issue with the power steering

The EHPAS pump is fully integrated with the module, sensors, pressure limiter and reservoir.  It is supplied as a complete assembly with no user serviceable internals.

The only external sensor is the steering angle sensor which is on the rack.  You may be able to 'relearn' that using Forscan on the replacement rack.  It may need to learn where the ends of the rack are, so it can reduce pressure at full lock.

Fortunately the EHPAS pump was very common and used on many Fords of this era, so they can be sourced second hand for around £30 and are easy to replace.  Just be aware a used pump may need to be coded to the car using Forscan.