Disclaimer: Links on this page pointing to Amazon, eBay and other sites may include affiliate code. If you click them and make a purchase, we may earn a small commission.
Heat is an issue and fluid cavitation. In my case my PS pump would get very loud off-road even with my Icon PS res/cooler. The fill line is way too low on the reservoir.
No matter then level you will get pressure bleed from the top and I found filling it to 7/8 full has not caused any serious spillage and my PS pump has remained very quiet off-road.
I have checked the fluid temp several times while off-road and it's never hot so I know my PS cooler is working good. It was the fluid that would bounce around (not being full) and creating air pockets.
Two runs now and so far no PS issues!
The fluid "bouncing" around in the reservoir is a constant issue with my truck, and I don't run it hard. I've heard of an old school racer trick where you put a stainless sponge in the reservoir to act as baffles and keep the fluid some what still. I've looked for stainless sponges that are made to act as fluid baffles, but I can only find metal sponges that you use in the kitchen,a and EXPENSIVE custom aircraft parts.
I've also toyed with the idea of "overfilling" the reservoir, but I'm no hydraulic engineer. Glad to hear its has worked for you. Rebuilding my entire system this weekend. Going to try the 7/8th full thing. My only concern is it building too much pressure and burping out my Icon resi's purge valve thing. Any troubles with that?