Ok, so a few months back my power steering began being noisy, soon followed by the fluid aerating real bad and pushing out the cap. So, I checked the lines, flushed the system, and it still did it. So I bought a rebuilt pump and installed it yesterday, used a vacuum pump to draw the old fluid out and the new fluid in until it was all new fluid. Also, I put brand new lines on just in case. Well, I start it up and begin doing the lock to lock to get any remaining air out. I noticed that when going to the extreme locks(the last 1/8th of a turn) it would become extremely difficult to and made put the pump under tremendous load as it became quite noisy. I did the back and forth maybe 3 minutes and shut the truck off. Low and behold, I hear the spewing and sure enough it was bubbling out of the cap again. So, is it safe to say my steering box is bad?

 

That is a distinct possibility..

 

Well, after spending 6 hours slowly bleeding all the air out of the system, I think it is good to go. Holy crap, Ive never dealt with such a PITA power steering system. Even though the lines were brand spanking new, I pulled the lines, checked the O-Rings, and replaced one because it had the tiniest evidence of being pinched. Then I torqued them as hard as I could. On the return line I put 4 hose clamps on for good measure.... Then I spent hours bleeding it little by little with the cap off. It aerated like 6 times because huge air pockets would come to the top and all the fluid would suddenly drop before I could add more. But, in the end, I finally got it. Although I think there may still be a little trapped in there because a little bit of aerated fluid floates to the top when I take it all the way to the lock. Not sure if that is normal though since I believe thats when pressure is at its highest. Its gonna sit for a couple weeks and if it aerates again when I get back from Ireland, then Ill know the box is jacked. Another thing I did notice was that even though the motion in the steering wheel was smooth and I couldnt feel anything, I could see the wheels shutter when going left to right.

 

Good job bro. Ya got a hell of alot of patience. Now it time to play.....