"What is the proper procedure for draining, flushing and refilling the 809 power steering system. I can't seem to find the steps within the TM's."
Im not sure as to the proper procedure but I would unhook the return line from the power steering pump and place it in a jug start the truck and have one person turn the wheel back and forth while you pour new power steering fluid in the resovior once the return line appears to be pumping new fluid, turn off the engine annd reconnect the return line to the pump.
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start the truck again have one person turn the wheel back and forth while you add fluid to the cold mark. I would suggest driving the truck a couple miles so the fluid gets hot then check the fluid with the engine running and top off if neccessary
I think you will BURN up a pump doing it this way because it is a recirculating system, you will NOT pump a lot out before the pump is DRY.
In order to drain and flush the system, the following needs to be done
1--Remove the lines from the right steer cylinder, remove rod end from right steer arm, work rod totally both directions, this clears the cylinder,
2--THEN remove the gear box ends of the cylinder lines, blow air though, this clears these lines,
3--THEN remove the pump lines from the gear box blow air though all 4 ports while turning the steering wheel (helps to be jacked up)
4--THEN drain the pump ( turning the motor makes it easy BUT DO NOT START)
5--WHEN you are all done making a MESS, connect the lines, reinstall the cylinder rod, fill the pump, let sit, refill, let sit, on and on till the pump stays full, then turn the motor over (DO NOT START) while turning the steering wheel lock to lock, keep a eye on the pump, fill as needed, till it stays full ( do not let it suck air) NOW start and run, LOOK for LEAKS while turning lock to lock, the pump should stay full
ONE more thing, DON'T FORGET TO REMOVE THE JACKS