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1992 240 power steering leak at rack and high pressure hose

eurobikenut

Member
Joined
Mar 31, 2023
I recently had a steering fluid leak and discovered the high pressure (the crimped one) was the source and replaced it, using the original copper washers. I noticed that I still had a leak so, I took the banjo bolt loose and tried to get some new copper washers with no luck at autozone and o'reileys. So, I sanded both sides of the original copper washers to make them flat again, put it back together and tightened the banjo bolt tighter than the first time (I have broken banjo bolts before so, I was not tightening it super tight.) It is still leaking and I tightened it very tight. Is this a problem area? Maybe I need to tighten it down tighter with new copper washers? does anyone have the dimensions for the copper washers? Thanks!

EUROBIKENUT
 
Put it back together with some thread sealant smeared on the sealing surfaces of both the washers and the bolts. That usually takes care of pesky leaks from fittings. I use loctite 592 but any quality thread sealant should work. Put some gloves on and make a mess but it works well.
 
The high pressure banjo crush washer is 14 x 21 x 1.5 mm. The return fitting crush washer is 16 x 22 x 1.5 mm. I have them in stock.
 
^^

I was waiting for you to chime in. OP, spend the money. Your time has to be worth more than the $0.17/hour TB going rate. Buy 2 sets, just in case.
 
DOH! Ok so I ASSumed the leak was the high pressure crimped hose that was leaking because it was covered with oil but I got new copper washers from hiperfauto, and thread sealer, and it is still leaking. I am now suspecting the other hose as the culprit, spraying the high pressure hose, giving the illusion of it leaking. Haven't gotten around to looking at it again to confirm. Feeling pretty stupid but, with a car with over 400k miles on it, lots of things are covered in old oil, Thanks!

Eurobikenut
 
Not uncommon for return hose to seep @ clamp end of hose, also, sometimes they sweat through the hose itself. Might be able to just tighten clamp. Best route is to replace the return hose (with factory hose), and replace both upper and lower clamps. Good luck!
 
Thanks for the reply! I checked the return hose and it is dry on the outside, not leaking at the clamp at the reservoir. Return hose is dry all the way from the reservoir to the rack. I will jack it up and get a closer look at the rack end. Thanks!

Eurobikenut
 
Ok, turns out that the short metal line has a rust pinhole in it that runs across the rack. Not the longer one (yet) that is clamped in place with the U-bolt. Going to the wanted forum to try to find one. Thanks fellas!

Eurobikenut
 
OK I have scoured the online parts diagrams trying to find this steel line that I need and I have found a picture but no part# associated with it. It's the bottom line on the rack in the picture. Not a very good description and picture but it's the best I can do. Trying to get this line part#. Thanks!

Eurobike
 
OK I have scoured the online parts diagrams trying to find this steel line that I need and I have found a picture but no part# associated with it. It's the bottom line on the rack in the picture. Not a very good description and picture but it's the best I can do. Trying to get this line part#. Thanks!

Eurobikeyoub
You could always adapt it to an line if you can’t find oe
 
OK sorry, I tried to post the picture (never have put a pic on a forum before) and it said :"file too large" or something like that, so the picture didn't load. Anyway, there are 2 metal lines on the rack, it is the shorter line. It is a CAM rack. I USED to have 5 240 parts cars until some a-----e scrapped them. Long story, or I would have the part. Thanks!

Eurobikenut
 
hiperfauto,
Thanks so much for the part #'s for the power steering lines! I would think that the longer one is the more expensive one but, I will figure it out. Can't really tell from the picture. Thanks!

Eurobikenut
 
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