[s-cars] Pump to Accumulator hose rebuilding

[SJM Autotechnik]

Tom,

I have had several of these pump to accumulator hoses rebuilt by a local 
Hydraulic hose shop that caters to the operators of heavy equipment, Earth 
moving, caterpillar, Semi-Trucks etc.

The outer protective foam rubber can be sliced down the middle to remove, 
and then later zip tied back around the repaired hose.

The original crimped on ferrule at each end of the rubber section, can be 
cut off by "carefully" using a hack saw or by using a dremel cutting wheel, 
while avoiding cutting into the original metal banjo fitting ends which are 
barbed where they are inserted into the hose.

There is nothing special about this hose with the exception that there is a 
double barbed metal pipe in the middle of the hose which has an orifice on 
one end, and a screen on the other end.

The center crimp ferrule can be cut off, then the hose is then sliced open 
and this double barbed pipe is removed. The hydraulic shop can insert the 
double barbed pipe half way down into the new piece of replacement hose, 
and have a new ferrule crimped onto the  center of the hose at the location 
of this pipe.

Before having the hose rebuilt, you should note the relative position of 
the two banjo fitting ends  to each other and make sure the hydraulic shop 
maintains the same position when installing the new piece of hose and 
machine crimping each end.

I like to cut off the 3 ferrules and remove the double barbed pipe myself, 
to avoid having the hydraulic shop damage the the two metal end sections.

My local shop uses replacement hose rated to 3000psi, the Audi factory 
manual states the system pressure test should show 140 bar (2030psi) at the 
brake servo port.

Some shops won't do the standard replacement using the machine crimped 
ferrules, and will require that they braze on new threaded ends to the 
metal pipes with banjo fittings, so it will accept a standard replacement 
section of hose which already has crimped on fittings.

HTH

Scott Mockry
SJM Autotechnik
<http://www.sjmautotechnik.com/>www.SJMAutotechnik.<http://www.sjmautotechnik.com/>com