Hey guys!

I'm new here. Had a quick search and couldn't find anything related to my problem so here's a new thread. A4 1.8 1996

A few weeks ago I was driving to university and as I almost arrived I heard a metallic noise and felt the steering wheel stiffen out. The power steering pump went. Fluid was being sprayed everywhere. So my Dad and I ordered a new pump and after waiting a week we swapped it out ourselves (was pretty fun considering I've never really done much work on cars before). We were hoping that would be that. But when we went to crank the engine for the first time to make sure everything was in order, fluid was still spewing out! This time I deduced it was coming from the return line hose - it has a hole at the end (just before the rubber pipe connects to the plastic pipe which then passes around the radiator).

We jacked the car up to try and get a look underneath and follow the return line so that we can see how to remove it but it connects to a metal pipe and trails behind the engine (to the steering rack I presume).

We have no idea how to get it out/what the part # is so that we can order a new one.. I was wondering whether we could fix the pipe (possibly through splicing the rubber part?) my Dad reckons we can't as it is a high pressure pipe and would leak instantly.

Any help would be appreciated. Have scoured the internet and can't find any guides to replace the return line hose. Really miss driving my car as it has been out of action for the past 3 weeks

 

You need to jack the car up and put it on jack stands. Then take the left side wheel off to gain access to the steering rack. Most likely you will need to move the rack forward to gain access to the banjo bolts that hold the power steering pressure hose on. It may be possible to get at the banjo bolts if you have swivel sockets and the right extensions without having to move the rack. To move the rack you have to unhook it from the steering column and unbolt it from the subframe and also unbolt the tie rod ends.

Here is a link with instructions on how to remove the steering rack. Read over it and you should be able to figure out how to unbolt the pressure hose. Good luck.

AudiWorld Tech Articles

 

I think that you mean the "supply hose". I've changed that on our Passat 1.8T pretty much as ccs suggests- but without having to move the rack. The problem isn't removing the banjo bolt, which does need a U-jointed socket to access from below, but putting it back on with the new hose, because there is really no way to do this by hand, from what I remember. The trick I used is to pre-install the banjo bolt with sealing washers on the hose end, then use a rubber band to hold it together, with the last few threads exposed. Now, with someone reaching into the engine compartment to hold and move the hose, you watch through the access in the wheel well, and then fit your socket on the banjo bolt. You should also remove the plastic cover in the wheel well where the tie-rod comes through, for best access. When the banjo bolt's threads are started, use a long, hooked-end piece of wire such as from a cloths hanger, to grab and pull off the rubber band. Tighten the bolt and proceed to attach the other end of the hose at the pump.