I'm into replacing my steering rack ('90 760GLT). The replacement is a reman Cam/TRW design. I've separated the pressure and return hoses at the banjo bolts and am trying to source and replace the copper crush washers. Using a Vernier caliper, I'm looking at four different washer sizes.

I first attempted to anneal the old washers with a propane torch I have on hand and gave up. This AM I called the most local Volvo dealership for replacements. I was told that there are only two sizes. I called TASCA and they also confirmed that there are only two sizes. Maybe I'm too fussy. One size is OEM p/n 18671 they say. An internet search gives: OD 21mm, ID 14.4. The other size is OEM p/n 11996. An internet search gives: OD 22mm, ID 16mm. My caliper indicates OD of 20mm for the former and 20.5 for latter for the washers removed from the return hose. And, yes I know that OD is not the critical dimension, but I'm not convinced that there are only two washer sizes for the two hoses.

TASCA noted that one p/n (two washers) was for the return hose and the other (two washers) was for the pressure hose. I wish I could show them in person that this doesn't cut it. Using the return hose's banjo bolt as an example, I can easily pass the largest ID over its threads and 16mm shoulder to lay flat under the bolt head. The second largest washer will, with twisting, move along the bolt's threads and but not pass along the 16mm shaft. As for the smaller diameter pressure hose's banjo bolt, the same holds for its original washers, that is, the smaller two of the four washers. It's shoulder has a diameter of 14mm.

Any ideas or experiences relating to steering gear crush washers you can share?

For the fun of Volvos,
Mike

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'92 245DL, '90 760 GLT