Thanx Rainman, perfect diagnosis! (eom) (archive)

reservoir. The fluid wont flow through when cold because its too thick. Empty all the fluid out of the reservoir. ( i use a cheap turkey baster to suck it out)Remove the upper clip that holds the metal screen in and remove the rest of the fluid. Remove the next clip and spring. Then remove the metal plate covering the filter. Remove the filter and replace. I've cleaned them with brake spray cleaner and blown them out the opposite way of the fluid flow, but it only seems to last a week or so that way. Put all new fluid in and try it.
The first time I start my M635 each day, there is a horrendous groaning noise coming from the power steering. Its worse as I turn the wheel side to side. It goes away once the car is warmed up, about 5 minutes down the road. The fluid is full, and there arent any major leaks, accept a tiny one near the resevoir. The problem does not re-occur throughout the day, even once the car has sat for an hour or more. Had a similar problem with an E30 once, but it was also leaking fluid like crazy right from the unit itself, shortly after, I needed a rebuild. Any thoughts? I would hate to be facing a major rebuild by letting this go on, but no ideas where to start.

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