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Leaking power steering from high pressure line (940, 1994) 900 1994

With spring in the air, I am now contemplating some repairs I need to do to a 1994 Volvo 940.

The car is leaking power steering fluid at a good rate from the high pressure line. The leak looks like it is coming from where the line connects to the rack at the bottom of the car and is due to general rust and deterioration. I have checked with the FAQ and a Volvo parts guy and determined that i have a Koyo rack.

I am told by Volvo they no longer make the Koyo compatible high pressure steering fluid line and FCP also does not carry this part. I have purchased a steering line that is supposed to fit with a Koyo rack.

My question is, how difficult is it to replace this line? Lots of discussion in the FAQ about replacing/ rebuilding the rack but not much about replacing a line.

Has anyone does this? How difficult is it? Advice welcomed.








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    Leaking power steering from high pressure line (940, 1994) 900 1994

    I dropped the rack in my 940 for a rebuild and reinstalled it. Re-attaching the lines seemed like the easy part. The project really shouldn't be difficult.

    I would be curious if a shop could repair your line. When I lived in FL, there were several great resources locally for a/c line repair, power steering lines and other high pressure lines.
    --
    94 944 na 319,000 and rolling; 05 XC90 2.5t AWD for the wife; 97 Chevy Suburban 3/4 ton 6.5 diesel daily driver; 92 745t beautiful condition (sold); 88 764t failed experiment (sold)








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    Leaking power steering from high pressure line (940, 1994) 900 1994

    I'm not familiar with the Koyo rack but the basic job of changing the high pressure hose is not difficult if it is similar to the other brand racks. First compare the two hoses to determine correct length and type fittings at both ends. If the connecting point at the rack uses a "banjo" type fitting I would only warn that it is possible to overtighten such a fitting to the point of breaking it (it's a hollow tube after all). Use new copper washers (need not be from Volvo--a well equipped hardware store should have an assortment). The fit around the banjo bolt should be as close as possible. If none are available you can use a propane torch to anneal (re-arranges the molecules) the old ones.
    Remove the lower splash shield and set a large enough pan underneath the car. Use a suction bulb to remove as much fluid from the pump as possible. Start at the lower fitting -- loosen and let the fluid drain. Move on to the pump connection when draining is done. Fit the new hose with the orientation of the banjo fitting same as the original.
    When done fitting the new hose refill the pump reservoir and start the motor. Spin the steering wheel lock to lock--use even, slow motion. Back and forth - 5 to 10 times should be plenty to bleed out air. Recheck fluid level and road test. -- Dave








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      Leaking power steering from high pressure line (940, 1994) 900 1994

      The job is not that hard except:

      1. You'd need to crawl underneath the car (use sturdy jacks for safety)
      2. Remove engine undercover
      3. Remove old banjo fitting underneath the rack
      4. Expect still more steering fluid comes out of hoses and rack - even though you've tried your darn best to empty it all at the reservoir and pump
      5. (And this is the hardest part!) Fitting the banjo part of the NEW hose onto the rack.
      6. Fit the other end of the new pressure hose onto the pump
      7. Refit engine undercover
      8. Refill with new steering fluid

      If you're using aftermaket part then it would take longer, maybe 2 - 3 hours. This because the pipe bends done poorly by the manufacturer. You'd have to crawl out, rebend the piping yourself and crawl back under trying to fit again. And again. All the while fluid still dripping out to mess with your tools and hands. Very slippery. Lots of wonderful words too.

      If you're using OE part, fitment is easy, about 1 - 2 hours overall the job is done.

      You might find the old high pressure hose has a long curlicue bend (long 'U-shaped' hose that goes underneath the engine oil pan before coming back to rack) to absorb high pressure whereas the new hose doesn't. This classic part is rarely available online now thus owners have to make do with the shorter high pressure hose version. However the classic part is available at brick/mortar Volvo parts store if you have one in your town.

      You might experience some occasional steering vibrations when turning during parking, using the new shorter hose version. This doesn't happen with the classic part.

      Amarin.








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        Leaking power steering from high pressure line (940, 1994) 900 1994

        Dear Amarin,

        Hope you're well. Should I presume you meant to add "and jack-stands" in Instruction #1? I don't rely on jacks alone, howerver sturdy, when I have to under a vehicle.

        I had assumed that an aftermarket high-pressure power steering hose (e.g., Edelmann) would be as long as and shaped identically to the Volvo Brand product.

        Thank you for the excellent instructions, which should go into the FAQs!

        Yours faithfully,

        Spook







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