Hello,

I have a '99 XC with a 120,000 miles on it. I find that every year or so, I have to replace the cap on the power steering reservoir. I'll find a fine mist of ATF fluid spraying from underneath the cap onto the reservoir, and then it leaks down the side. I've check the level of ATF/power steering fluid to make sure it is not over filled. I've also checked to make sure there isn't a crack in the reservoir itself (though I have replaced it once or twice, where a leak developed along the seam). I now have a plastic bag that contains 4 "old Power Steering Reservoir caps" and it looks like I'll be adding #5 soon.

When I first install a new power steering fluid cap, the spray/leak from the cap stops for a while. But then it returns again. It seems that at the cap gets "used" i.e. the twisting motion of opening/closing of the cap, a "trench" develops in the green colored gasket that lines the inside of the cap. The trench becomes deep enough over time to allow ATF/power steering fluid to get passed it. At least that's my theory. Still, I have two '96 850s with 200K and 300K miles on them, and I'm still using the original power steering caps on each car.

Has any one else had this experience? If so, other than buying another cap and needlessly enriching my local Volvo dealer, does any one have any suggestions? Thanks to all who reply.

Hugh

Hugh