Date:         Wed, 28 Oct 2009 20:56:17 -0400
Reply-To:     Robert Stewart <robertmstewart@MAC.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Robert Stewart <robertmstewart@MAC.COM>
Subject:      Re: Think I have sprung a leak in my powersteering lines! Need
              some guidance please.
In-Reply-To:  <DABC46E3-A22B-4311-A81A-128947A5DD80@mac.com>
Content-Type: text/plain; charset=ISO-8859-1; format=flowed; delsp=yes

Hello Everyone,

I fixed the HP line with an amazing high quality Parker hose with a  
standard operating PSI up to 4750 with a max burst dynamic rate of 4x  

times that. Static burst is 3x that base amount. I believe it is  
called the 301/201 3/8 ID hose with steel braided inner core and a  
tough wrap around the steel braided hose.

I had the hose made by PowerTech Hyrdaulics which is an authorized  
Parker dealer.

The fittings come direct from Germany so they are bit more expensive  
but the whole package for the HP line being 11.5', Steel braided line  

with Toughgard wrap, and 2 straight fittings cost me with assembly  
$79.72 and took me 10 minutes to walk in, order and walk out.  So in  
the end I saved myself  $105 dollars just by driving 30 minutes to the  

local store.

here's how to do it.

Here's the samba link as well:
http://www.thesamba.com/vw/forum/viewtopic.php?p=4157550&highlight=#4157550

I used the following part #'s

High Pressure Line Connectors
(2) Female connectors on each end.*
Female DIN 24° Cone Swivel
Light Series With O-Ring
Hose I.D.=3/8
Hose I.D.=9.50(mm)
THREAD SIZE=M16X1.5
NUT HEX=19MM
LENGTH=2.06"
CUT-OFF=1.15"
CUT-OFF=(mm)29.16
Brands of Fittings & Model #'s:
Gates #
6G10FDLORX
G25645-0610 $18
Parker Part 6-10L XHU86-S Metric swivel adaptor.
Parker part 10691N-6-6 HP crimp swivel nut $5.50 each


Hose Size and Pressure Rating needed for the High Pressure & Low  
Pressure Hoses:
Based on basic research I have found the following - can ANYONE confirm?
Sizes:
High Pressure - 3/8" ID


Pressure
High Pressure 4000 PSI Minimum
Low Pressure 400 PSI

Hose Type:
Braided Hydraulic Line ( Optional Stainless Steel )
1/2" Bend Radius
Brands & Model #'s:
Gates Mfg. part-- part # G25645-0610

Length:
High Pressure - 11.5' long
Low Pressure - 13' long

Other Recommendations:
1. If you don't purchase a steel braided reinforced hose place Rock  
Guard Coil Around Hoses that are exposed under the van to prevent  
damage to the hoses.



Parker Hose information:

Parker hose product numbers: 6-10L XHU86-S, Metric fitting that goes  
on the HP side of rack.$18 per fitting.

919-6, Stainless Steel braided HP hydraulic hose.$4 per foot.

10691N-6-6 Crimp end coupler to attach SS hose to Metric fitting 6-10L  

HXU86-S.$5.50 each

The reason that there are two fittings on each side of the hose is  
that Parker does not make a Metric crimp fitting for HP SS braided  
hose. They do make a metic crimp fitting for HP hudraulic hose part #  

1C343-10-6, but this will not work with the SS braided hose.

Gates Part #G25645-0610 $18.00 each.
Parker cross ref. Part 6-10L XHU86-S Metric swivel adaptor.

Parker part 10691N-6-6 HP crimp swivel nut $5.50 each, this is  
attached to the HP hose and then this screws onto the metric fittings  

on each side.

Braided SS, the braid is on the outside of the hose and the inner hose  

is teflon..........$4.00 per foot. This is also 3/8" hose.

On Oct 26, 2009, at 1:06 PM, Robert Stewart wrote:

> 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