[s-cars] Power steering hose (was Spokane HOH)

[Theodore Chen]

i did the job last night.  it took me about an hour, working at a leisurely pace.  the supposed M16 crush washers i picked up at NAPA turned out to be just a bit too small (i think they were SAE, not metric) and required some persuasion to get them over the banjo bolt.  this is at the pump end, which is fairly easy to do, so if it leaks, i'll get the right M16 crush washers and redo it.

to answer my own question: the banjo bolts are indeed different diameters (M16 at pump end, M14 at rack end) but have the same size hex (19mm or 3/4").  when i loosened the banjo at the rack end, power steering fluid began dripping on my CV boot, so i immediately covered the boot with newspaper.

i installed the rack end of the hose first.  standing on a stool made it easier to reach into the engine compartment.  it took me three tries to get the banjo bolt started.  i dropped a crush washer on the first attempt, but the washer was caught by the paper towels i'd stuffed under the work area, so i didn't have to fish in the recesses of the engine compartment.  on the next try, i put a dab of permatex gasket adhesive on the washer, but it wasn't enough and the washer fell off again.  on the third try, i thoroughly coated the washer and banjo with permatex, and the washer stayed on until i was able to get the bolt threaded.

i had a bit more trouble than i expected with attaching the hose at the pump end, because i was fighting a stiff hose that resisted my attempts to align the banjo with the threaded hole in the pump.

all in all, i'd rate this job about a 3 for difficulty on a scale of 1 to 10.  i used no four-letter words at all and got no
scratches, cuts, or bruises.  i didn't have to lie under the car with
crud falling on my face.  it really helps to have a ratcheting
combination wrench, especially a stubby one that allows more movement.

-teddy

----- Original Message ----
From: "jtoms493 at comcast.net" <jtoms493 at comcast.net>
To: s-car-list at audifans.com; s-car-list at audifans.com
Sent: Thursday, January 17, 2008 10:05:22 PM
Subject: Re: [s-cars] Power steering hose (was Spokane HOH)


Teddy, did this job last year. I like you thought I needed at least a
 new banjo bolt on the rack side. I just checked my invoice and my parts
 stash. As best I can tell and with looking at the hose I installed and
 the bolts used, I used the existing bolts with new crush washers
 because the new hose did not have the integral rubber washers (as you noted).
 
My parts invoice for this job included 4A1-422-893-Q for the hose, (2)
 N-013-814-9 washers, and (2) N-013-844-4 washers. The banjo bolts I
 bought and never used were N-903-580-03 and WHT-000-507. These were only
 2-3 dollars each when I purchase them last year, so I bought them just
 in case they were needed, but I never used them. 
Good luck with the install, the crush washers make for a fun contortion
 to hold them on each side of the banjo bolt while you are trying the
 money shot to screw in the bolt. I suspect there's some adhesive you
 could use to hold them in place(?) Watch where your fuel line is snipped
 along the firewall from the fuel line recall, I shed some blood
 installing the banjo bolt on the rack.

John Tomlinson
93 S4
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