Power Steering Reservoir

Remove and replace the power steering fluid reservoir on a 1966 Chevrolet Corvette with 327ci V8 engine, including fluid drainage and system refill.

Warnings

Tools required

Parts

• Power steering reservoir × 1 — Use OEM specification or GM 7800524
• Hose clamps (if originals are damaged) × 2 — 5/8 inch worm gear clamps

Fluids

• GM Power Steering Fluid — 1 qt

Preparation

1. Park vehicle on level surface and set parking brake.
2. Allow engine to cool if recently operated.
3. Open hood and secure with prop rod.
4. Place protective covering over driver's side fender area.
5. Position drain pan beneath work area to catch fluid spillage.

Procedure

1. 1

   Remove reservoir cap and drain fluid
   Remove the power steering reservoir cap by turning counterclockwise. Use a turkey baster or fluid transfer pump to remove as much fluid as possible from the reservoir into a drain pan. This will minimize spillage during hose removal.
2. 2

   Disconnect return hose from reservoir
   Locate the return hose (lower hose) connection at the bottom of the reservoir. Use line clamp pliers to clamp the hose before disconnection if desired to prevent fluid flow. Loosen the hose clamp using a flathead screwdriver or socket, then carefully pull the hose off the reservoir nipple. Direct the hose end into the drain pan and allow remaining fluid to drain.
3. 3

   Disconnect supply hose from reservoir
   Locate the supply hose connection at the reservoir. This hose runs to the power steering pump. Loosen the hose clamp and carefully remove the hose from the reservoir nipple. Position the hose end upward or plug it temporarily to minimize fluid loss.
4. 4

   Remove reservoir mounting bracket bolt
   Locate the single mounting bracket bolt that secures the reservoir to the inner fender panel. Remove this bolt using the appropriate socket. On 1966 Corvettes, this is typically a 3/8 inch or 7/16 inch hex head bolt.
5. 5

   Remove reservoir from vehicle
   Lift the reservoir out of the mounting bracket and remove it from the engine compartment. Be prepared for residual fluid to drain from the reservoir. Inspect the mounting bracket for damage or excessive corrosion; clean as necessary.
6. 6

   Inspect hoses and clamps
   Examine both power steering hoses for cracks, soft spots, or deterioration. Check hose clamps for rust or damage. Replace any compromised components. The original hoses on 1966 Corvettes are often deteriorated after 50+ years and should be replaced as preventive maintenance.
7. 7

   Install new reservoir in mounting bracket
   Position the new reservoir into the mounting bracket on the inner fender panel. Align the mounting hole and install the bracket bolt. Tighten the bolt snugly but do not overtighten, as the reservoir body or bracket can crack. Hand-tight plus 1/4 turn with a ratchet is sufficient.
8. 8

   Connect supply hose to reservoir
   Push the supply hose firmly onto the upper nipple of the reservoir until it seats completely. Position the hose clamp over the hose connection point and tighten securely with a flathead screwdriver. Ensure the clamp is positioned at least 1/4 inch from the hose end.
9. 9

   Connect return hose to reservoir
   Push the return hose firmly onto the lower nipple of the reservoir until fully seated. Position and tighten the hose clamp securely. Remove any hose clamp pliers that were installed earlier.
10. 10

    Fill reservoir with power steering fluid
    Using a funnel, fill the reservoir with the manufacturer-specified power steering fluid (1966 Corvettes typically use automatic transmission fluid, Type A/Dexron) to the FULL COLD mark or appropriate fill level on the reservoir/dipstick. The system capacity is approximately 1 quart total, and the reservoir will initially accept about 0.5 to 0.75 quarts before reaching the fill line.
11. 11

    Bleed air from power steering system
    With the engine off, turn the steering wheel fully lock-to-lock (from full left to full right) 10 times. Check the fluid level and add fluid as needed to maintain the FULL COLD mark. This process removes air from the system. The fluid level will drop as air is displaced.
12. 12

    Start engine and complete bleeding procedure
    Start the engine and allow it to idle. Turn the steering wheel slowly from lock to lock 3 times while the engine is running. Check for leaks at all hose connections. Observe the fluid in the reservoir; it should not be excessively foamy. If significant foam is present, continue turning the wheel slowly until foam subsides.
13. 13

    Check fluid level and top off
    With the engine at operating temperature, check the fluid level. It should be at or near the full mark for hot conditions on the reservoir or dipstick. Add fluid as necessary to bring to proper level. Reinstall the reservoir cap securely.

Reassembly

1. Torque specifications are not provided for this component; use appropriate hand-tight installation torque for mounting hardware.
2. Ensure all hose clamps are positioned correctly and tightened to prevent leaks.
3. Verify reservoir cap is installed and sealed properly.

Verification

• Start the engine and verify no leaks are present at the reservoir or hose connections.
• Turn the steering wheel through full range of motion and confirm smooth operation without binding or noise.
• Check fluid level with engine at operating temperature; level should be at FULL HOT mark.
• Verify steering wheel returns to center properly after turning.
• Check for absence of excessive foam in reservoir, which would indicate remaining air in the system.

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