Leaky Oil Cooler

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My Cougar's power steering oilpump started whining and the steering action felt like it had no oil. I know the power steering lines under the engine are quite rusty so I expected them to have gone, but it seemed to be the cooler. The oily mess now showed me where the culprit was. I investigated an (red) oil leak before, but never saw much oil in other places than the tranny servo cover. Wiggled that and cleaned it and I thought I was OK, ...not so.After getting the cooler out and draining the ATF, pressure tested the cooler and found a leak in the place where the steel hinges go round the aluminium tube. Galvanic corrosion obviously killed it in our road-salt happy country. Because second hand coolers will have the same defects and a new one is something about 150 euro's I decided to do a repair attempt. After all a power steering cooler can't be that critical in our climate.Took out the cooler part, found some turbulence thingies in the old pipe and put these in an aluminium tube which I had lying around. Welded the tube in between pressure tested it, welded on some hinges, mounted the cooler, with the tranny cooler, hoses, clamps, oil.Then started the engine and verry soon realised I skipped a step... I should have pressure tested the assembly after welding the hinges.The only leak I made welding was not on the pipe, but apparently I welded through the pipe when I was welding the hinge.So back under the car, hoses off, oil out etc...   Reweld hinge, dont't forget to pressure test.Car's fine now.
Reply:Ford used to use a power steering cooler that was plumbed into the return line.  It sat above the power steering pump & in the airflow off the radiator.  Cooler itself was rather small, maybe 2" wide by 4-5" tall.  If you feel the need to run a cooler, I would get one of those & plumb it in.  Not very complicated to do, just tap into the return line to the pump.MarkI haven't always been a nurse........Craftsman 12"x36" LatheEnco G-30B MillHobart Handler 175Lincoln WeldandPower 225 AC/DC G-7 CV/CCAdd a Foot Pedal to a Harbor Freight Chicago Electric 165A DC TIG PapaLion's Gate Build
Reply:Good job fixing a part thats no longer availableRegistered Six OffenderHome of the Buzzin Half Dozen