Complete power steering fluid drain, flush, and refill service for the 1966 Corvette 327 V8, including system inspection and air purging.

Warnings

Tools required

Parts

• Power steering pump gasket (if equipped) × 1 — Use OEM specification

Fluids

• GM Power Steering Fluid — 1.5 qt

Preparation

1. Park vehicle on level surface and set parking brake firmly
2. Chock rear wheels securely
3. Turn steering wheel fully left, then fully right to identify full range of motion and listen for abnormal noises
4. Raise front of vehicle with floor jack and support on jack stands at frame rails
5. Locate power steering pump on front driver side of engine, driven by crankshaft via V-belt
6. Locate power steering reservoir (integral to pump body on 1966 Saginaw pump)
7. Inspect all visible hoses and fittings for leaks, cracks, or deterioration before service

Procedure

1. 1

   Remove old fluid from reservoir
   Using a turkey baster or fluid transfer pump, extract as much old power steering fluid as possible from the reservoir. The 1966 Corvette Saginaw pump has an integral reservoir accessed via the fill cap on top of the pump body. Remove all accessible fluid, typically 0.5-0.75 quarts from the reservoir itself.
2. 2

   Disconnect return hose
   Locate the low-pressure return hose at the power steering pump. This is the hose that returns fluid from the steering gear back to the pump reservoir. Loosen the hose clamp and carefully disconnect the return hose from the pump fitting. Position the hose end into a drain pan. Plug the pump return port with a clean rubber cap or shop rag to prevent debris entry.
3. 3

   Drain system through return line
   With the return hose disconnected and positioned in a drain pan, have an assistant start the engine briefly (2-3 seconds maximum) to pump old fluid out through the disconnected return line. DO NOT let pump run dry. Alternatively, turn the steering wheel lock-to-lock several times with the engine off to manually push fluid through the system. Expect approximately 0.5-0.75 quarts to drain.
4. 4

   Reconnect return hose
   Remove the plug from the pump return port. Reconnect the return hose to the power steering pump fitting and secure with the hose clamp. Ensure the clamp is positioned properly on the barbed fitting and tighten securely by hand (these are typically worm-drive hose clamps requiring only snug tightness).
5. 5

   Refill reservoir with fresh fluid
   Remove the reservoir fill cap from the top of the power steering pump. Pour fresh Dexron-type ATF (the factory-specified fluid for the 1966 Saginaw system) into the reservoir until it reaches the FULL COLD mark on the dipstick (typically integrated into the cap). Initial fill will be approximately 1 quart. Do not overfill.
6. 6

   Purge air from system (engine off method)
   With the engine still off and front wheels raised, turn the steering wheel slowly from full left to full right and back 15-20 times. This circulates fluid through the system and begins displacing trapped air. Check reservoir level after every 5 turns and add fluid as needed to maintain FULL COLD level. Watch for bubbles in the reservoir indicating air purging.
7. 7

   Start engine and continue purging
   Start the engine and allow it to idle. Turn the steering wheel slowly from lock to lock 10-15 times while monitoring the reservoir fluid level. Add fluid as necessary to maintain proper level. The fluid level will drop as the system fills completely. Listen for pump whining or groaning which indicates remaining air in the system.
8. 8

   Check for leaks and proper operation
   With the engine running, inspect all power steering hose connections, pump body, and steering gear for signs of leakage. Verify smooth steering operation with no abnormal noise, binding, or excessive effort. Turn steering wheel to center position and verify fluid level is at FULL HOT mark with engine at operating temperature.
9. 9

   Road test and final verification
   Lower vehicle from jack stands. Perform a brief road test including slow-speed parking lot maneuvers and moderate-speed turns in both directions. Verify smooth power assist with no unusual sounds or feedback through the steering wheel. After test drive, recheck fluid level with engine hot and at idle; top off if necessary to FULL HOT mark.

Reassembly

1. Ensure reservoir cap is installed securely with dipstick fully seated
2. Verify all hose clamps are tight and properly positioned
3. Clean any spilled power steering fluid from engine bay and pump housing

Verification

• Fluid level at FULL HOT mark with engine running and at operating temperature
• Steering wheel turns smoothly with consistent power assist in both directions
• No whining, groaning, or cavitation noise from power steering pump
• No visible leaks at pump, hoses, fittings, or steering gear
• Steering returns to center properly after turns
• No air bubbles visible in reservoir fluid with engine running

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