Date:         Mon, 26 Oct 2009 13:06:13 -0400
Reply-To:     Robert Stewart <robertmstewart@MAC.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Robert Stewart <robertmstewart@MAC.COM>
Subject:      Think I have sprung a leak in my powersteering lines! Need some
              guidance please.
Content-Type: text/plain; charset=US-ASCII; format=flowed; delsp=yes

Hi everyone,

I need some guidance please.

I have a 2.1L Automatic 1988 Wolfsburg. Just rebuilt the engine and
had all new hoses put on.

Prior to the install the power steering pump had a minor leak, now
after the rebuild no leak.

2 days ago in pouring rain I noticed the steering was very stiff. So I
looked at the ATF fluid in the Power Steering Tank. It was almost
empty so I filled it.

10 minutes later it was making noise when trying to turn at slow
speeds pulling from the parking lot. So I filled again with some Lucas
Stop leak and topped it off with some more ATF.

Got home and it was empty. So I look today to see if I can see
anything. I had the lines replaced the fat & thin lines with copper
ones in 2007 I believe. I am noticing some red fluid around some areas
of the lines but I can't be sure where its really coming from.

Where are the key areas to look for leaks?

Will it kill my pump if I drive it with some fluid in it that drains
out over the time of me driving it to get it fixed?

I assume the best thing to do is just replace them with Hydraulic lines?

Walrus from the Samba posted some details on having them custom made
but I need someone to confirm his data please. He stated they should
run around $40.

I assume I need to go to hydraulic shop or tractor shop to get them
made?

Walrus's instructions for building 2 Power Steering lines:
http://www.thesamba.com/vw/forum/viewtopic.php?t=147368&highlight=steering+fluid+leak

High Press line
11.5' long, two female compression fittings, 16x1.5mm
Needs to be flex industrial stainless braided rated 4200lb. I.D. is
5/16".
I believe I used 3/8". Connects where metal line junctions with the
1.5' section of hose held onto pump with banjo bolt.

Low Press line
13' long, Needs to be rated 400lb? 1/2" I believe.
Connects from Reservoir to rack. I cut the pipe 4 inches from rack and
connected by sliding hose over pipe and used hose clamps. Other end
hose clamps to reservoir.

Is this an easy job for one person to do in their backyard?
How long should it take?

If I brought the lines to a mechanic with a lift how long should it
take to replace the lines and add the fluid?

Do the lines need to be bled out or anything? A special process for
testing it and making sure its installed properly?

Thanks,
Robert
NY