p80 1999 2000 power steering hose 1282852 9485359 notes

[abscate]

Quick notes on handling the lines during a rack replacement.

Note on 1999 models the pressure and return lines are different from -1998. The return line comes up aft of the engine and dumps into the reservoir clipped to the coolant bottle. The pressure fitting into the pump is also different

I put the new steering rack in, then found I couldn’t get the lines on even with the subframe dropped. I spent 8 hours on this. The lines route close to each other and foul when you try to put them in.

I finally pulled the whole rack again and succeeded with the following strategy.

In the bench I attached the return line first , then the pressure line. On the 1999 return line, the fitting is a soft alloy and it is really easy to strip both the threads snd the bolt head

After getting them firm , I then backed them off two flats or 120 degrees. This allows the hard lines to move in the fittings.

It is then possible to install the rack with the lines attached. Feed the right side in, bring the left side around the transmission and then feed the tie rods into place. Start the rack nuts in place. Feed the return line up and the pressure line up. The pressure line goes up near the dipstick then over the ac line. That one is a bit of a hassle to route but it’s doable.

Make sure you don’t lose o rings while fussing with the lines

Once you get the rack firm on the subframe , tighten your two flats each to firm
Up the lines. They are oring flange connections not flares.

Pressure line 19 mm wrench
16 x 1.5 mm thread o ring flange seal in both ends
Return line 17mm wrench
18x 1.5 mm o ring flange seal on rack end

[abscate]

This finally permeated by dense skull. The correct tool for this job is metric flare nut crows feet wrenches, such as these.

Firefox was the Maker on this one.

[FireFox31]

Here's a link to my power steering high pressure input line replacement. The flare nut crows feet were amazing.

The hardest part was getting the line in place with the rack installed. I had to plan my moves a few steps in advance. It was something like feeding in the J hook rack end over the rack upside down, rotating the pile 180 degrees which swung the right angle part on a wide arc (must be done with the car 5' up on a lift), then getting the J in place at the rack. It's impossible to describe.

The critical bit was ensuring that the new hard lines were bent exactly like the old ones, placing them on a table overlapping to confirm. The new one was a fight to get in place when it was bent wrong. When bent correctly, even the J was tricky until it was bent perfectly.

[abscate]

On the 1999 style you can install the rack with the lines threaded and loose. Highly recommended

[matthew1]

Added to the big, beautiful VRD.