Author Topic: PAS fluid leakage from tbox  (Read 5266 times)

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Offline webboy

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PAS fluid leakage from tbox
« on: November 20, 2010, 19:50:27 PM »
Hi all.
Sorry if there is an answer to this question somewhere, but I couldn't find it.

Vehicle: Opel Calibra C20LET (blacktop) '96 4x4

So, yesterday I took my Cali for a wash and when it was over I started the engine to move it out of the washing garage. I heard a strange noise from under the hood. Stopped the engine, opened the bonnet and started the engine again. The strange noise was coming from a PAS fluid pump, but it stopped after 5-10 seconds.

When I moved the car reverse out of the washing garage I notice a giant PAS fluid spot on the floor. I also noticed that 4x4 light on the dashboard stayed on and I also noticed that I don;t have power assisted steering any more.

Parked the car near by, bought a canister of PAS fluid. When I opened the PAS fluid reservoir I noticed it's half empty, so I filled it up using the protocol (ignition ON, pumped the brake pad for 25 times and then filled it up to the "hot" level since the engine was hot). When I started the engine again, all fluid leaked on the floor again. I checked beneath the car and I noticed the fluid is coming out from the hose connected to the transfer box.

I did diagnostics with Tech1 device and I got error code:
74 Power Assisted Steering PAS pressure less than 10 bar

Well, that's kind of logic as all the PAS fluid leaked out (well, not all of it, but about 800ml)

I changed the Pressure Accumulator Bulb today and the problem remained the same. After change, again I filled the PAS fluid reservoir and started the engine, but again, 800ml of PAS fluid I poured in got out from that tbox hose I mentioned.

Now the bulb I put was not new so there is a chance It's not operational.

However, I'm wondering what can cause PAS fluid to leak out of the tbox hose??

Any ideas?


Everything else on the car works just fine. So it's just that 4x4 light is on and 4x4 drive is disengaged (I've tried it and it doesn't work) and power assisted steering doesn't work :)

Offline webboy

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Re: PAS fluid leakage from tbox
« Reply #1 on: November 20, 2010, 19:53:44 PM »
Just to point out something.

The hose from tbox I mentioned has never been connected to anywhere, so it's not broken or something. I guess it is used to release the PAS fluid when there is a higher pressure than it should be.

Online callyman

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Re: PAS fluid leakage from tbox
« Reply #2 on: November 20, 2010, 23:06:58 PM »
If you mean the small black hose that pushes onto the top of the tx box is leaking, im afraid your ram seal has blown in the tx box. (Now front wheel drive only)
Remove fuse 19 and refill the PAS reservoir.

A permanent fix/bypass is to screw together the high pressure pipes that go into the accumulator assembly then join the two smaller return pipes with a 90 degree piece of 100mm copper pipe and jubilee/hose clips.



Offline webboy

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Re: PAS fluid leakage from tbox
« Reply #3 on: November 20, 2010, 23:49:05 PM »
Yeah, I'm too afraid that's the hose :(((

If I pull out the F19 and fill in the pAS fluid... I'll get my power assisted steering back at least, but the 4x4 drive will remain disengaged.... right?

Do you have any images for that permanent fix you mentioned? ... and what actually does it fix?

Anyway..... is there any other way to get my 4x4 drive back engaged except replacing the transfer box?

Is there anything else that could go wrong except the ram seal??? I've read some documents from cav16 website and it seems that error code 74 indicates a faulty pressure switch in the control valve???? Can I just replace that?


Online callyman

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Re: PAS fluid leakage from tbox
« Reply #4 on: November 21, 2010, 00:03:44 AM »
Yes pulling the fuse will restore your steering, but it doesnt always stop fluid loss totally.

Just join the two thick pipes together and the thin ones together with the 10mm pipe.
Here is a photo of mine (when mine went wrong)




The PAS fluid can only come out of the breather pipe (on top of tx box) by getting past the ram seal. The ONLY way to restore the 4x4 is with a working tx box.
After you have removed the accumulator assembly, find the two spade connectors that where attached to the pressure switch on the back of the assembly and join them together with some wire.
This will stop the 4x4 dash light from flashing, but it will stay lit.

Offline Martin.

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Re: PAS fluid leakage from tbox
« Reply #5 on: November 21, 2010, 01:02:22 AM »
Callyman is spot on I'm afraid!

as this happend to him not long ago!  :(

sorry to hear you lost your 4x4 :'(
best of luck getting it going again, If you decide to do!

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Offline webboy

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Re: PAS fluid leakage from tbox
« Reply #6 on: November 21, 2010, 02:33:14 AM »
Nonononno guys.. I'm not giving up on it that easily :)

I do have a spare tbox, so I'll just replace it.

Offline Martin.

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Re: PAS fluid leakage from tbox
« Reply #7 on: November 21, 2010, 02:36:04 AM »
Nonononno guys.. I'm not giving up on it that easily :)

I do have a spare tbox, so I'll just replace it.

glad to hear it, nice one
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Offline Dajanitor

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Re: PAS fluid leakage from tbox
« Reply #8 on: November 21, 2010, 02:53:19 AM »
If you mean the small black hose that pushes onto the top of the tx box is leaking, im afraid your ram seal has blown in the tx box.

Sorry if i sound thick as sh*t, but i know nothing ot t/x boxes, but if its just a seal, cant you just replace this seal?

Offline webboy

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Re: PAS fluid leakage from tbox
« Reply #9 on: November 21, 2010, 03:21:11 AM »
Also... now I'm thinking something......

I'm trying to understand how the control valve is working......

So, the fluid comes from the hydraulic accumulator (pressure regulator) (aka. the bulb) into the control valve. If the valve has power (12v) the el. magnetic valve will open and the fluid will go to the tbox creating a pressure to move the clutch and engage the rear drive......

And we have a pressure switch which controls the pressure and if it is more than needed, it signals the valve to close a bit and pass the fluid onto the steering.....

So, maybe that pressure switch went wrong and the fluid is being continuously pumped into the tbox causing the max pressure and since the tbox can not handle more pressure it releases the fluid on top through that black hose.... and since the pressure switch is faulty... the 4x4 computer thinks there is no pressure at all causing a 74 error code.


what do you think?

Sorry If I got it all wrong... I'm actually a web developer got interested into mechanics :)

Offline strizh108

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Re: PAS fluid leakage from tbox
« Reply #10 on: November 23, 2010, 02:26:36 AM »
No. You're mistaken, man
The operating pressure for txb is regulating by valves in regulator. Then fluid under pressure comes to control valve. Txb has no fluid circulating in it. It is one-hose hydraulic system which delivers pressurise the fluid in txb. When solenoid in control valve is operated it closes return line and fluid presses on the ram. When solenoid is off the fluid passes to tank by return line. Solenoid turns off only with brake pedal operated or 4WD fault. The pressure switch opens on low pressure telling ECU to turn off solenoid. 74 fault code is because the pressure is lower than 10bar needed. It can't be achieved because of leakage in txb, and ECU turns off 4WD by turning off solenoid.  Your switch is not defective. It works well! Otherwise you will have all the fluid on the flood under the car.
The only cause of fluid leeking from breather tube is bleeding ram seal, unfortunately

Offline strizh108

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Re: PAS fluid leakage from tbox
« Reply #11 on: November 23, 2010, 10:42:02 AM »
sorry, one correction
pressure switch contacts are closed when there is no pressure 10bar
contacts are opened - the pressure is 10bar and higher

and found found some fault causes when then 74 code is appeared:
- Vicious coupling blown (oil squirting out the breather pipe)  or
- Clutch Pressure Plate Assembly - Seal blown (oil squirting out of the breather pipe)
 -PAS pump / accumulator blown (PAS working ?)
- Solenoid/wire broken / fuse / shift block
- Other electric faults can cause the 4x4 light to come on eg, brake pedal switch, speed input, engine rpm, tx box temperature

There are first two which according to to your case

Offline webboy

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Re: PAS fluid leakage from tbox
« Reply #12 on: November 23, 2010, 13:42:09 PM »
Sh***t I should have admitted this to myself already - the tbox is damaged, no matter how hard I hoped it's not :)

Now, let's just hope it's just the seal... by talking to Richard (Cav16) and the guys in Dorfbrunnen-Garage (that are actually manufacturing tboxes for Adam Opel) I understood that I can replace the seals form the spare txb I have. It's from the C20XE Caly, so I can only take the ram seal out of it and not the VC :(

O yeah.. and let's hope the spare tbox I have doesn't have a blown seals too (I got it for free from the guy who broke the propeller shaft and never fixed it).

So, there are a lot of things here that require hooping :D


And.. if everything fails.. I guess I'll have to decide between 2 possible solutions:

1) Get a locking kit and lock the mtf**ing tbox :D or...
2) Sell my wife and buy a sports transfer box from Richard or Dorfbrunnen-Garage :D

A tricky decision, huh? :)

Anyway, thanks for the info guys.

Offline tommygards

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Re: PAS fluid leakage from tbox
« Reply #13 on: November 23, 2010, 13:45:37 PM »

2) Sell my wife and buy a sports transfer box from Richard or Dorfbrunnen-Garage :D


3) buy a qrew transfer box that are better, stronger and cheaper.

Offline webboy

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Re: PAS fluid leakage from tbox
« Reply #14 on: November 23, 2010, 14:33:58 PM »
Thx Tommy,

I can't find the user "qrew" here... do you have any contact?

Online callyman

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Re: PAS fluid leakage from tbox
« Reply #15 on: November 23, 2010, 14:43:28 PM »
Sell my wife and buy a sports transfer box

I did That but unfortunatley the wife wouldn't leave. lol

Offline tommygards

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Re: PAS fluid leakage from tbox
« Reply #16 on: November 23, 2010, 17:32:45 PM »
Thx Tommy,

I can't find the user "qrew" here... do you have any contact?

not easy to contact directly as he's from sweden or something.  the best contact is Chip who sells them on his behalf in the uk and is in contact with him.  Unless you are running high power though then there wont be much noticeable difference between that and a standard box as when they are both looked after properly then both work fine, just the Qrew is capable of high power.

Offline webboy

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Re: PAS fluid leakage from tbox
« Reply #17 on: November 23, 2010, 17:41:52 PM »
I think I found out that you were asking about Qrew's tbox as well.... so did you get it? experiences with it?


By the way, I'm from Serbia, so ordering from Sweden or Uk doesn't make much difference to me :)

Offline tommygards

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Re: PAS fluid leakage from tbox
« Reply #18 on: November 23, 2010, 18:29:30 PM »
I think I found out that you were asking about Qrew's tbox as well.... so did you get it? experiences with it?


By the way, I'm from Serbia, so ordering from Sweden or Uk doesn't make much difference to me :)

ah okay

yeah ive got it and its on my car.  havnt managed to test it much yet as am still getting the car back on the road but from the few miles i have done on it then it has seemed awesome. Another person that bought 1 and put it on an astra manages to light up all 4 wheels and if you search for 'qrew calibra' on youtube then there are videos of him spinning all 4 wheels with the same transfer box so you can see what it is capable of.

Offline webboy

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Re: PAS fluid leakage from tbox
« Reply #19 on: November 24, 2010, 11:44:20 AM »
Can anyone tell me what's the price of Qrew's tbox in the UK?


 


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