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Discussion Starter #1 (Edited)
The PS return hose came off the outlet from the steering box. Not sure how/why it came off, I'm pretty sure I slid it on good when I replaced the hoses last year, and it has a clamp on it (one of those cheap OEM clamps that you squeeze with pliers to release).

And by "lucky failure", I mean that it came off fairly close to when I parked, as both the power steering and power brakes worked fine when I parked, but power steering was gone when I pulled out (so all the fluid drained out while parked). So the PS pump seems fine, as it wasn't driven any significant time without fluid (yay).

Put the hose back on, filled it up with the ridiculously expensive PS fluid from a gas station, and back in business.

Now I just have to clean all the PS fluid that was sprayed around the engine compartment, and figure out why that hose came off and make sure it is fully on the outlet tube...

And by "another lucky failure", maybe two years ago or so, a rear brake line rubbed against the tire (Russell Stainless Steel flex lines, I bought them as an "upgrade", but they are crappy, lines aren't measured properly, fittings aren't bent like OEM, missing supports, they are craptastic), but the brake pedal failed (went to floor because virtually all the fluid was gone) as I was pulling out of my garage, so I was going slowly and not towing anything, so it still stopped with the brake pedal. If the same thing had happened at speed, say for a stop light, no chance it would have stopped the truck in time...
 

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Sounds like you got lucky. I had a fairly new Napa Pressurized feed hose fail on a Powersmoke Hydroboost system a few years ago running 15000 lbs down the road. Scary... almost ass-ended a semi truck/trailer at highway speed.... On return lines whether it be power steering or otherwise it is common for rubberized line shrinkage to occur over the course of a few heat cycles and I would expect to have to tighten the hose clamps 1 or 2 times after installing. If you still get leakage after tightening by all means find a better product its your life.
 

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Discussion Starter #3
The next day I went back and made sure the hose was on good, and it turns out to be the line going to the PS cooler, which I don't recall having to remove to replace the 3 main lines. The hose itself looked completely fine including the inside. I suppose I might have removed it to replace on the other lines and just never got it on good enough...
 

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Discussion Starter #4
Ugh. This is crazy. That same PS line just came off again.

This time, I had to drive about a mile to get some PS fluid, so the pump is no longer quite as happy to be in use (definitely is whining now).

I know the hose was fully installed, and the fitting as the ridge towards the edge, and the spring clamp has plenty of spring (as it sucked getting it back on).

It's like it is slowly vibrating off over about a year or so.

Tomorrow, I'm taking off the spring clamp and putting on a regular hose clamp.
 

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Discussion Starter #5
Double ugh.


Third year in a row, the hose comes off. I put off putting the hose clamp on, cuz it was really cold, and forgot to do it when it was warm out.


So, once again, it gets cold out (below -20C), and I guess the return hose gets a bit more pressure in it (and, as a pattern, I have just realized it happens soon after I pull a U-turn in the truck).


This time, the spring clamp also came off the hose, and, as luck would have it, I happened to have some hose clamps that were close to the right size, so I put one of them on, so it shouldn't come off again.
 

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Discussion Starter #6 (Edited)
And I'm back.

So, driving around again in the cold (-25C), and again out of PS fluid. The previous issue with the non-pressurized hose (I believe it's the one between the hydroboost and the steering gear) coming off the steering gear fitting didn't happen, the hose hasn't budged with the new hose clamp I put on. Now, I think (it's dark, frikin cold, and everything in the area is covered in PS fluid) it's one of the high-pressure lines to the hydroboost unit (the one that screws into the top of the hydroboost) that has failed now, not totally, it takes maybe 30 min to an hour of driving before the PS pump is begging for more fluid.

All these lines are new from NAPA back in 2016, so this is kind of premature. I'll replace the line tomorrow or Monday, but is there anything that could be causing the system to get over-pressurized, like a screen somewhere that is partly plugged, that only happens when the PS fluid is really cold (and I've only put in name-brand PS fluid, I think it's always been Prestone, and never have put in anything else like ATF)?

In general, both the power steering and brakes feel and work good (brake pedal is maybe a little soft).
 

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And I'm back.

So, driving around again in the cold (-25C), and again out of PS fluid. The previous issue with the non-pressurized hose (I believe it's the one between the hydroboost and the steering gear) coming off the steering gear fitting didn't happen, the hose hasn't budged with the new hose clamp I put on. Now, I think (it's dark, frikin cold, and everything in the area is covered in PS fluid) it's one of the high-pressure lines to the hydroboost unit (the one that screws into the top of the hydroboost) that has failed now, not totally, it takes maybe 30 min to an hour of driving before the PS pump is begging for more fluid.

All these lines are new from NAPA back in 2016, so this is kind of premature. I'll replace the line tomorrow or Monday, but is there anything that could be causing the system to get over-pressurized, like a screen somewhere that is partly plugged, that only happens when the PS fluid is really cold (and I've only put in name-brand PS fluid, I think it's always been Prestone, and never have put in anything else like ATF)?

In general, both the power steering and brakes feel and work good (brake pedal is maybe a little soft).
FWIW, I have been having to go over my lines yearly as well. Mine have never come off, but every line at the booster will eventually start to seep. I replace the o-rings on the psi lines and never over tighten them, that I can tell. And I use the exact right size and material o-rings. They will still seep a little eventually. New o-rings and another year. The low psi side I too added worm gear hose clamps as the spring loaded ones would not hold psi on these low psi side lines. And, the return line from the booster will still always start to seep in a year. I tighten the hose clamp and replace the o-ring on the stud. I really do not know how I can be doing this wrong. But yep, every year or 2 the tiny seep annoys me and I go through it all again. Note that NONE of the connections at the gear ever leak or seep.

NONE of this happened from new. BUT, the high psi lines always leaked from the factory. Not until I replaced all of them did I start having issues with these o-rings and hose clamped parts seeping in a year or so. I assume it must be something I'm doing. But what? If you over-tighten o-rings they will deform or get cut and leak. So I start out snug and tighten a bit more if and when they start to seep. And the hose clamps, no idea how that can be wrong. I tighten them very snug and then if / when they start to seep I tighten them to the point they are gonna break if I go any further.

Idk. I'll watch this thread and see if folks have ideas. I just keep telling myself I guess this truck insists on not keeping all the PS fluid inside. It is super tiny seeps, but seeps nonetheless. Also, I added a ps cooler when I replaced all the lines. Wished I hadn't as it was never needed. And just one more reason that I could be getting all these seeps for at least one at the cooler goes this same tighten, seep, tighten loop. Perhaps it's all more line to push and pull fluid from than designed. I replaced the 2006 OEM booster with a 2011 or 2012 OEM booster.
 

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Discussion Starter #8
It's not likely you adding the cooler, as my truck came with the PS cooler from the factory... course, I should replace mine, because it's lines are seeping...
 

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Hey Davester, first let me say how impressed I was with your 2wd to 4wd conversion. I followed it and could see it was something I would never tackle! Knowing you know so much makes me hesitate to clarify a few things, but . . . I will.
... The previous issue with the non-pressurized hose (I believe it's the one between the hydroboost and the steering gear) coming off the steering gear fitting didn't happen, the hose hasn't budged with the new hose clamp I put on. ...
I'm quite sure the line between the hydroboost and steering gear is high-pressure. So, both of the lines on top near the firewall are high-pressure (one from the pump, and one to the steering gear). That's why they should be crimped and not just held with a hose clamp. The third line from the hydroboost, with a hose clamp, is low-pressure back to the pump.

I was having power steering fluid making a real mess. I put in:
- a new pump (nothing wrong with old one but I wanted the improved 2008 pump)
- new hoses (2 high-pressure by Gates and 1 return from the steering gear to the pump, AC/Delco but obviously all 3 hoses were made at the same facility; even had the same help phone number), and
- new hydroboost (old one leaking a lot, and wanted improved 2011 model).

Reading horror stories of bad reman'd steering gears, I paid to have it done (first time anyone else has touched my truck). Supposedly an AC/Delco reman'd gear and so far it is working perfectly (smooth, no slop, no drips).

So, for the first time in a long time, I'm not dripping power steering fluid!! We'll see how long that lasts.

I re-used the spring clamps on the return hoses. Now you're trying to scare me!!

(Added note: Davester and MP . . . I know how we (yeah, me too) are, but I've decided you have to be okay with seeps, as long it doesn't drip. A coating on the hose really is not that bad!)
 
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Discussion Starter #10
There's 2 pressurized lines connected to the Hydroboost, and 1 non-pressurized one, and I'm using the correct, pre-formed, crimped lines, it's not some hack-job.


I'm going through the FSM, and I think the non-pressurized line from the Hydroboost is going to the wrong part (the manual shows it goes to the PS pump, but I believe currently on the truck, it's going to the steering gear). I'll trace all the lines and compare them with the manual to get them to the right spots.
 

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The high psi lines at the gear I really cranked on and so those should have leaked. But never did. Maybe I should over crank the rest and see. I think I will next time. But yea Jake111, I really need to learn to accept seeps on a diesel. My buddy looks at it and says the same thing - seeps are nothing to be concerned with.
 

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I was concerned because I put the hoses on with their new o-rings, then changed out the hydroboost and reused them (new ones didn't come with the new hydroboost). But they still looked good/new. Then I had the steering gear replaced and I'm sure they reused them. I would say I tightened "more than just snug" but not as tight as possible. I think I read 35-ish ft-lbs somewhere, but I still went with "feel". And what do you think the professional did on the steering gear? I put a wrench on and they didn't move when applying my "feel" torque.

But no leaks that I can (or am willing to) see!! I've got a 3k mile trip coming up, so I'll see how it all looks in a month.

Think of those seeps as a protective coating!!
 
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Discussion Starter #13
Just to follow up, the PS pump to hydroboost pressure line had a small break in the middle of it, under the plastic shielding. Just enough to let a small stream of fluid come out when the engine is running, so I could fill it up, and drive to the store to get the replacement line.



Fortunately, I have a heated garage to work in, because it only sucked balled to get the hose fitting started in the PS pump, as it seems to take 3 hands in a 1-hand space to hold it just right, and then have to use a wrench to start it in the threads.


It would have been, uh, worse, to have to do it outside in -25C weather with a bit of drifting snow...


I won't have to worry about that corner of the truck rusting for awhile, it's all coated with PS fluid.


Now, I'm surprised that some of you are having problems with these lines seeping at the fittings. I've only had that happen where the hose is crimped to the metal lines (on all the lines, PS, transmission, engine oil). The fittings don't leak for me. But I also torque them to spec using a crowsfoot wrench to 20 ft-lbs (couldn't do the one on the PS pump this time, as now there's a diff in the way)...


And I was mistaken about lines being incorrectly routed, as the non-pressurized line from the hydroboost on my truck is correctly routed to the PS pump (I had though it was routed to the PS gear nipple, but it wasn't).


I'll have to keep an eye on it for awhile, and once it warms up a bit, I'll wash all that fluid off everything and hopefully it'll be good for awhile.


If something like this happens again next winter, I think I'll install a new PS pump. And I might just install a used take-off line from my parts truck, and order an ACDelco line (or set of lines) from rockauto [ouch, the Edelmann line I just about for $40, is $15 from rockauto].
 

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A permanent fix for weeping PS lines is available. Replace the rubber sections with a quality single wire hydraulic hose like many of us have to the trans cooler lines -the hose size is just smaller....

I like aeroquip FC300 hose, field installable jic ends and versilflare tube adapter fittings.
 

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Discussion Starter #15
Ugh. This happened again.


The supposedly low-pressure return line from the hydroboost that goes to the fitting on top of the steering box popped off again. I had put a better clamp on it when I replaced the PS cooler, one with a screw/nut to clamp together (vs worm gear or the oem spring type), and the fitting itself has a lip at the top, so it really shouldn't pop off.


But, for whatever reason, when it's cold out (-28C yesterday), it will sometimes just pop off. It didn't the previous couple of days, when the temp was even colder...


Again, I was lucky to notice it immediately, as it likely popped off just as I started the truck to go and the steering was hard, so I could shut it off, and had enough PS fluid to refill it after reconnecting the hose, but I don't know what to do next.


I've only put in PS fluid, but maybe next I'll try either a thinner fluid and/or a different fitting on the steering gear that will grip the hose better.
 

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Ugh. This happened again.


The supposedly low-pressure return line from the hydroboost that goes to the fitting on top of the steering box popped off again. I had put a better clamp on it when I replaced the PS cooler, one with a screw/nut to clamp together (vs worm gear or the oem spring type), and the fitting itself has a lip at the top, so it really shouldn't pop off.


But, for whatever reason, when it's cold out (-28C yesterday), it will sometimes just pop off. It didn't the previous couple of days, when the temp was even colder...


Again, I was lucky to notice it immediately, as it likely popped off just as I started the truck to go and the steering was hard, so I could shut it off, and had enough PS fluid to refill it after reconnecting the hose, but I don't know what to do next.


I've only put in PS fluid, but maybe next I'll try either a thinner fluid and/or a different fitting on the steering gear that will grip the hose better.
I hear ya. I have mine so clamped down that the hose is squished. I expect it to cut into the hose eventually. But it just likes to seep so I've lost patience and cranked the hell out of the worm gear hose clamp.

Now, when it seeps, it'll be at the o-ring like it's supposed to. :D

I need to go add a second hose clamp to maybe keep the hose from eventually cutting....

Btw, none of the spring clamps would hold enough psi (not even the OEM) so I went with the worm gear. And yep, I know that's not right. All I can think is NONE of this was an issue when the OEM lines were leaking from their factory crimps and before I added the aftermarket non-needed PS cooler. Idk...
 

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Could the p/s line be slightly shorter than they should be, so when cold and tight turning are flexing slightly and tugging at fitting? I know that some aftermarket hoses get stiffer when cold and will not give as much flexing when cold. We've had a couple lines fail on equipment during this last -40 Bullsh*t weather we are having up here in Drayton Valley and that is what we have attributed the failures to...
 

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Discussion Starter #18
Well, the line isn't stretched at all, it's not visibly damaged,either externally or the interior where it goes on the fitting, and it's between the steering gear and the hydroboost, so it's not directly subject engine movement.


From what I can tell, it appears to just be pushed off the fitting, likely due to excessive pressure from the fluid being cold and something off a bit somewhere in the system.


Everything works fine when it's hooked up again. It seems to happen when I start up the vehicle, after it's sat for maybe 1/2 hr or so. I'm not doing anything that should tax the system, like turning the wheel to full-lock or jamming down on the brake pedal.


When it warms up a bit, I'll try swapping the fitting with one from my parts truck,as it's the only one that's failing like this. The similar fittings on the PS cooler (I refurbished one, and it just has hoses pushed on, then clamped down), and they don't even weep.
 

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Discussion Starter #19
Looked at the hose today, it had pushed up the fitting and appeared to be just hanging on with the clamp just at the rib at the end of the fitting. Took the hose off, and added a worm-gear hose clamp to it as well (so now there's two clamps on it), pushed it all the way onto the fitting, and now there's a clamp at each of the lips/ribs (wrong terms) to hold the hose on.
 

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Just curious if it is possible for you to take a picture of this hose fitting from hell. I have not had a single problem with my PS in 13 years but you have me worried that maybe I need to take a look at it.
 
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