Replacing power steering hoses on D2
 

Hello everyone,

I discovered a small leak on thick supply hose that goes from the engine pump to the steering rack.
After reading horror stories how these oil lines fail due to rust etc. I wanted to replace them all.

But some hoses are not available any more from Audi for our RHD cars.
For example, the long return line 4D2422891C, which is also prone to leaking, is no longer available.

I was wondering if there is a company who can custom make those hoses and replace them ???
These hoses are not 'rocket science'. Surely, lots of companies do custom stuff for race cars, etc.
In the UK or in the Continental Europe.

Has anyone do this?

Thanks.

Hi Sergey

The motorsport sector is your best bet - look for an Earls supplier (or contact the company direct - they're based at Silverstone)

https://www.earls.co.uk/earls/contactus.html

I'm sure they'd be happy to produce parts from a pattern to keep on file for other requests (if they don't already have the specs)

Cheers

Adrian

There is one way valve inside one of the hoses, it is the feed hose from reservoir to the pump. Mine is a bit worth for wear and I wanted to replace it but new one was something like £192( that wa slike 10 years ago, might be no longer available) and any aftermarket/general usage hose would not have the valve so I am stuck with the old one just occasionally tightening clip by the reservoir as that's where the rubber is perished and leaking.

MJ and others (Neil or Annairs?) have been discussing having a hydraulic mob like Pirtek make hoses for the purpose with the appropriate valves and restrictors put where needed.
Haven't heard an update in a while, though a race hose mob would be as good as any.

The house with the swivel join/diameter reduction from the cooler to the reservoir on mine has a weep at the cooler and I'd like to replace it.
I'm assuming I could destroy the swaged join at the swivel and just replace the smaller diameter hose (oil rated) and use hose clamps to secure it (and get a bit of length back - it's a bit stretched at the moment)?

I have successfully repaired weeping return lines by removing the original swage crimps and replacing them with o-clamps, and then covering them with adhesive-lined heatshrink. As they're not under high pressure these clamps are fine. I use two per joint, offset by 90 degrees. The return is simply a plain hose with the reducer before it goes in to the cooler so not hard for a hose specialist to replicate. You'd lose the hard-line portion that runs along the rack itself and would have to use a P-clip to hold it to the rack, but its not that complicated.

Replicating the pressure hose however is considerably more challenging as it has a nozzle in the pump fitting which feeds an inner liner inside the main hydraulic hose. I've tried plain 10mm hydraulic hose and the pump howls constantly due to the lack of backpressure I think, and the steering is too light. It would need someone like HEL to manufacture a new pump-end fitting with the correct nozzle and then figure out how to do the hose-in-a-hose to replicate the factory setup. I do need to go and talk to HEL about the manual clutch hose so I'll take them a dismembered power steering hose at the same time and see what they think about it :)

Hi Mikki,

Great to know that return line can be treated separately from the supply line.

There are some companies that claim to make custom steering hose.
Some advertise themselves on eBay
Some of them claim they can re-use original steel ends!
http://www.spectrum-hose.co.uk/power-steering-hoses/

I'm OK to order two pressure hoses from Audi if still available.
I emailed my PTS contact.
Struggle to identify myself which ones are needed for my situation.
4D2 422 893 D expansion hose (flex. hose > vane type pump)
4D2 422 893 H expansion hose for vehicles with steering damper (flexible hose > steering box)
4D2 422 893 M expansion hose for vehicles without steering damper (flexible hose > steering box)

It looks like I need to select one from the last two...

I'm looking forward to seeing you soon Mikki to fix all these :)

I think the Mechanic that did mine used Pirtek for the one that was no longer available+++

Looks like Spectrum are worth a chat then. My local Pirtek are complete muppets and refuse to re-use original fittings but I only know them or HEL round here.

When I get some time I might give Spectrum a call and send them a couple of hoses for a quote +++ It would be good to find someone who can remanufacture them rather than re-engineering them from scratch.