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I think you have a classic case of hydraulic dead heading. You are trying to push more fluid through the system than the lines and pump will handle. I think you could install a hydraulic pressure relief valve in the pump output line and cure it. The max system pressure is supposed to be about 1160psi with the pump deadheading against a gauge, so I'd use a 1000-1500psi adj. relief valve


I would think it's a situation of mismatched flow. If the extra flow has to be dumped over a relief valve, this will generate heat. The change in energy state (pressurized) to a lower state (unpressurized) has to be converted into something and that's heat. I'd say the solution is to either use matched components or a big cooler.

Lee
'94 LS, 3.0 V6, Auto, completely stock