480 DB Hydraulic Steering Leak - Servo Box

Four Suns

Four Suns

Not a pot stirrer
TECHNICAL Contributor
Oct 4, 2006
10,533
Williamsburg, VA
Boat Info
2003 480 DB
Engines
QSM-11 Diesels
It's always good to check the bilge out before taking off in the morning and finding a gallon of hydraulic oil in a sump. My back sump by the rudders was filled with red fluid this morning and the the glass hydraulic fluid reservoir had about a 1/2" of fluid in it. I put in 2 quarts of SeaStar fluid, put some oil absorber pads under the ram, fired up an engine and turned the wheel a few time... and looksie here (crappy pics courtesy of iPhone):

IMG_0005-1.jpg


That can't be good... The hoses are all secure and the servo box on the top that has a small pushrod coming out was leaking oil. This is the servo box:

IMG_0006.jpg


and you can see the side where the oil is coming out:

IMG_0007.jpg


and


IMG_0008.jpg


I haven't searched much... but getting a new ram assembly back there is something like $2200.00... Ouch...

http://ww2.seastarsteering.com/PWR_STEER/power_dim.htm

I have an HC5801 on the boat...

I poked around a little and they seem to have a seal kit for the servo box although I couldn't really find a place that sells them. Seal kit part numbers are here:

http://ww2.seastarsteering.com/REPLACE_PARTS/db_ReplaceParts_display.php3?id=6

Anyone ever mess with these things? Spending $50 for a seal kit seems a little kinder on the wallet than $2200... plus looks like something I need for my spares kit.

Family is not real happy right now... boat is stuck at the dock.
 
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I found the instructions for the rebuild on that servo box...

http://ww2.seastarsteering.com/PDFs/886495D.pdf

"Detail C" is what is leaking.... Doesn't look too bad to replace other than figuring how to get that retaining ring (13) out. At a minimum, seal (12) is leaking or the gland assembly (13) where the push rod comes out is leaking. Don't suppose I can find a SeaStar dealer open that has this seal kit in stock on Memorial Day. Definitely one is going in the spares bag.

Hope all you 480 DB bastards that are out enjoying your boats today while I'm stuck at a dock get rained on.
 
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Thanks for the heads up. In fact was out enjoying the sun up here in Simcoe.

I had the same "red" fluid leak, but found it to be the trim tab reservoir leaking. Good thing I small enough to squeeze in right in the back to clean it up!

Another part for the spares bag as you say.

Cheers
 
Well... spent half the day pulling the thing out of a 100 degree bilge. How fun.

Now I need to find a seal kit.
 
Retaining ring (snap ring) pliers will remove those rings very easily.

I have these which are very nice since you don't have to keep fooling around with changing the tips to fit the ring. http://community.craftsman.com/Craftsman-Professional-12-pc-Ring-Pliers-Set-reviews
The downside is that big case isn't convenient to carry around in the tool box, so I have
these as well. They work just fine, you just need to change the tip to fit the ring. Okay for occasional use. http://www.craftsman.com/shc/s/p_10155_12602_00945358000P

Best regards,
Frank C
 
Teleflex said they won't have any new rams available until the end of July....

:wow:
 
Wow. That is a major bummer. Is there a workaround that can get you back on the water quicker?
 
Am I taking you off the list?
 
You could always bum a ride with Rick - so far, he doesn't have a date for the dance.
 
I called Teleflex and they said they had them in stock (but the ram assembly was not and would not be until end of July)... who pointed me to a distributor... who pointed me to a wholesaler... who pointed me to a local retailer... who could then special order it through the chain I just mentioned. Based on all the hands touching this, I'm assuming Teleflex has 48 cents in it.
 
God I hate that, having gone through the whole list , then only having to do it again and wait.....God I can't wait to have all these issues, I'm so freakin excited...
 
My ram was leaking a little bit. I purchased a complete seal kit from Jamestown, but it took forever.

On mine it it not the servo box, I think it is either the main ram seal between the piston and the endcap, or where the endcap seals to the cylinder. I am thinking the latter, because I tightened those four long rods, and now the leak is almost gone. I will wait till I have some time and rebuild the entire cylinder, I bought all the seals, and a new rubber boot.

I don't see a boot on yours, did it have one?
 
I've never had a rubber cover on my ram...

Also, I talked with Jamestown first and the guy there was nice enough but could not help me and said any seal kit would take 6 weeks to get. That's when I called Teleflex directly. It's not like they have to grow special rubber trees or something... geez.

As a side, I'll probably go ahead and get seals for the whole dang thing so I don't get left without a boat for a month and a half.
 
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I was going to suggest replacing all the seals, you may want to look into the boot also.

I had a rubber cover on my ram, but it ripped, maybe it was too small for the size of my ram?
 
Greg said:
I had a rubber cover on my ram, but it ripped, maybe it was too small for the size of my ram?
Click to expand...

I assumed we had the same size. Let's pull a tape measure out in AC this year and compare them.
 
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