Hydraulic pump fix.
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Hydraulic pump fix. - 4/29/2004 10:20:54 AM
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0fframp
Posts: 758
Joined: 3/9/2004
From: Swamplands of NJ
Status: offline
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If you have a 5000 or pre-92 100/200 you know what a pain it is. The seal kit at $60 is a joke, two months later and it is leaking again. Pentosin is not cheap either and sticky like molasses. The ZF rebuild, pricey, and is not guaranteed against leaks either.
I contacted Pentosin to find out what material is good to use as a replacement:
“… we would like to recommend the use of NBR elastomeres, but if you want you can use H-NBR or FPM materials.”
If you buy NBR O-rings from McMaster it will be lot cheaper, probably less than $10 per 100 but who wants to replace them every two months.
The fix is to use copper or aluminum crush washers similar to the ones used on FI and brake systems. The problem is finding the size 22mm X 18mm X 2mm. I made mine out of copper and aluminum .063” thick sheets and after 12+ months NO LEAKS. The hydraulic pump has two chambers with 8 pistons, two pistons are HIGH PRESSURE for the brake system and charge up the brake “bomb” these are a must. The other six are for power steering and are optional since the pressure is a lot lower.
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[Deleted] - 5/6/2004 10:20:01 AM
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Deleted User
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[Deleted by Admins]
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RE: Hydraulic pump fix. - 5/6/2004 10:57:54 AM
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0fframp
Posts: 758
Joined: 3/9/2004
From: Swamplands of NJ
Status: offline
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I am not sure if ATF was designed to work at the pressures that Audi pump put out. Most automatic transmissions rarely see anything over 600psi the hydraulic pump on 100/200 models can generate 2200 - 3000psi. But if it works without a problem, who am I to argue. As far tightening down the screw, been there done that, either the 5000 pumps puts out less pressure, the pump is worn or it is the physical properties of the ATF itself. I know that for me it didn't work, even after tightening it with the proper drag link it still leaked and not to mention I damaged a few screw caps. A trip to the local junkyard indicated that this is a popular fix as was indicated by all those striped caps and the pumps still had evidence of leakage.
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RE: Hydraulic pump fix. - 5/6/2004 2:24:51 PM
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uros@
Posts: 3
Joined: 5/10/2003
From: Spain
Status: offline
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On May 1987 I´d bougth a new Audi 100 KU 2223cc.,5 cyl (the 5000 US).
At the first trip (second day run) by very mountain curverd roads, the power steering presure line damper hose (the going to down line) begins to leak..
Warranty service replacement needs soon a second cure. OK from.
Late, the pump itself (maybe at two years) begin to leaks too. O rings replacement dont cure it at all. Less leaks, but leaks, sothat I must to add G2000 green gold frequently. A very cumbersome matter in a new car.
Late, the steeering rack goes in rubber prot. damage and leaks too.
Only the whole replacement fron the pump (from a yunk yard) and steering rack Audi serv.rebuilt could cure these leaks.
I deeply suspect for a non normal presure ratio in the system form the factory.
Nowadays, with 17 years and 267.000 Kms over. NO LEAKS.
Of course, because the car remains very reliable, I will use it as far as possible, beacuse it has been a hard battle, and I like this my second Audi car which engine keeps wonderfull.
I got shared my bad experince with several other european Audi 100 owners, and frequently have a similar experience.
I hope this a Audi cars lack, frequently reported. And not too easy to fix.
Helped..?
M. Urosa
Madrid.
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RE: Hydraulic pump fix. - 
