Finally, a nice day, and time to repair my leaky power steering hose.
At the same time, replacing the OEM '79 reservoir.

Here's the bad hose, it leaks at the metallic part in the middle. 2-3 drops everytime I turn the wheels. :


Ready to go!
Thanks a lot for those cover. First time to use them. Love them! They are so nice I fear to scratch them.


Old reservoir :


The level of oil was so low, didn't need to pump anything.


New hose :


New reservoir :


Now fast foward...
As my hands get horribly dirty, I don't hold the camera anymore.
Removing the old resevoir.
Come back line is stuck, hard time to remove it! But finally manage to do it.
Line to the pump easily remove.
Trash the old reservoir.
Notice that the faulty oil hose is horribly hard to find a way to unscrew it from the pump.
Second problem, it's a 17mm bolt, no good wrench around. Go buy a set of 11-22mm wrench.
Hard time to unscrew it as the timing belt is in the way.
Finally manage to unscrew it.
Now unscrewing the barril bolt, 19mm under the car, linked at the PS rack.
Hard time to unscrew, not a lot of place, and it's supposed to be a 22 pound bolt.
Changed the whole line!
Screw back the 19mm barril bolt at the rack....

Ooooooooh... my GOD!
ARRRRRRRGGGG!!!



WTFBBQPWNED!?

A whole month without my car running, and now I just broke it even more!
The other half of the bolt is still in the steering rack. NO IDEA how to remove it. I've no idea of the pressure I put on the bolt, and there was no space for a torque wrench, but obviously it was way too much.
Currently I just feel like banging my face on a wall or something.

Really hope someone has an idea to remove the other half...
And also hope that this kind of weird bolt isn't too hard to find.

 

I feel your pain....Just breathe...walk away for a few and go at it again. I've had many "things" go this way. Just don't give up!

 

what remains of it in the rack will unthread by hand very easily. You may find a chisel or screwdriver which fits in there tightly. Then you can use that to unscrew it.

You should be able to find one off a VW at a junkyard if you look.

 

I tried with something like that... It's stuck. After all, I applied enough pressure to break that bolt. I will try again tommorow. But I have little hope it will easily give up.

 

Didn't need to see this...I have mine to do soon.

 

Anybody know the spec of that banjo bolt?
(Yeah, I got to search a load to know that this bolt is named "banjo". All the porsche 928 workshop book talk about "hollow bolt", which make sense, but seeing the horribly low return of search on google for that, it's obvious it's not commonly named like that)

I know it's a 19 mm head... But that's it.

(Just noticed after reading many steering thread that I didn't remove the alternator, and didn't drop the sway bar. I guess dropping the sway bar would allow me to get the clearance needed to use a torque wrench)

 

The 2 banjo bolts at the steering rack are M14 threads by 1.5 pitch and is torqued to 22ftlbs. The Banjo at the PS pump is M18 X 1.5 threads and is torqued to 43ftlbs. The only thing I don't have is length of each of these bolts but might have an old one in the garage. Let me know if you need the length measurement and I'll see if I can find one and measure it.

 

If the banjo bolt was initally threaded in by hand ..... and went in easily before the wrench was applied, then the broken stub should slide out as Lizard suggested; however, if the wrench went on at the start and the bolt took effort to install ..... there is a chance that it was cross threaded. That would be neither easy nor cheap to correct.
Cross threading seemed to be a possibility, as I have never known one of these bolts to fail .... perhaps I've lived a sheltered life , for they only require enough torque to crush seal the copper washers.

 

I thread it by hand. Will try a few thing today.

 

x 2.

Good luck and keep us posted. -Ed

 

Those could probably help you out.

http://homerepair.about.com/od/inter..._extractor.htm

http://hand-tools.hardwarestore.com/...ctor-sets.aspx


Perhaps Tim Allen and his Bear-friend might come handy in situations like this, atleast they would sheer you up a bit.




/Tobias

 

Managed to removed the part of the bolt that was still in the rack.

And quite easily actually using :


Quite a nice tool actually. Fit right in, a few turn et voila!
Had to use the biggest one they had, because smaller one just pass completely in the bolt's hole.

And another good news, it appear my thread are still intact. From what I can see actually. Even the thread of the bolt is still in perfect shape :


Now I just need to find one.

BTW, Canadian Tires doesn't have a clue what a banjo bolt is. None of their mechanics ever saw one.
Tommorow I will try the local NAPA store. Hope to have more luck.

 

Try an hydraulic company, the know about banjobolts for sure.

/Tobias

 

That's weird! Glad it went "well"...

 

When I did my pressure hose the !@#$%^ tube nut into the pump was frozen to the tube, and I had to remove the pump completely just to get the hose off it. My hose rebuilder made a new one in 3 parts, so it was much easier to re-install - RHD hose is longer than LHD.
jp 83 Euro S AT 51k