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The check valve is in the tail gate. I pulled the cover and located the check valve. With a large syringe, determined that it would flow. With that removed, and with an assistant, verified that the pump has a strong flow into a bottle. Hooked it all up and pumped with the nozzle-cover [NC] off and no flow. The problem is that the passage through the wiper shaft was plugged up with rust. This was on the '03, the '04 had no such problem.
Taking the tail gate apart was a PIA. But you do not need to do this.
Get a steel wire that will fit into the shaft hole. If the passage is clear, you will be able to insert the wire to a depth of 5&3/4". At that point it is at the plastic elbow at the other end. If you remove the NC and cannot get the wire down that far, that is probably a rust blockage. You can put a pair of small vice grips to limit travel to 5&3/8" and try to open the hole. You can flatten the end of the wire to act like a spade bit and with the other end a 90 degree cut off with sharp edges, you can clear the hole. If you can get any flow, pump to clear debris, do that and continue until the bore feels smooth and clear. Flush clear before mounting NC to avoid fouling the nozzles.
So you can pull the cap, probe for 5&3/4". If clear, you do not have this problem. Otherwise, you should be able to clear the problem without taking the tail gate apart.
Why rust? Maybe if the fluid gets stale and looses alcohol you get rust and otherwise high alcohol content inhibits rust? I can see how rust flakes would block the spray nozzles.
posted by 65.71.16...
, Thu, 7 Feb 2013 22:17:03
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