Hey Bostig/Zetec Gang... Have a PS Question

[ShootingFish]

I have been dealing with a leak at the high pressure connection of the PS pump/coupling for some time now. It is really stating to annoy me, not to mention the wife is starting to complain about the oil stains on the asphalt in front of the house

I have tried a number of different washers and have yet to find anything that really does the job. Not to mention using the factory torque setting does noting more than create a bigger mess...

Solutions? Suggestions? I am currently using a 16mm washer with a rubberized ID and where that seemed to handle it at idle, as soon as I started to run it under load the seep came back.

Starting to lose my mind...

SF
_________________
SF

Props aren't just for boats....

'88 2WD ALH-TDI Westy
'90 Syncro 16 Doka

[thatvwbusguy]

Do you mean the connection at the pump itself with the banjo fitting? If memory serves, that connection uses a copper crush washer on each side of the fitting. I reused the washers that were on the fitting (even though that is usually not-so-good with crush washers) and have never lost a drop on my '85 Westy.
_________________
Jay Brown
'85 Zetec Westfalia
Newmarket, NH


If you want others to be happy, practice compassion.
If you want to be happy, practice compassion.

[ShootingFish]

That is the one... I have tried reusing the old washers... along with all kinds of other options and so far have had ZERO luck.

SF
_________________
SF

Props aren't just for boats....

'88 2WD ALH-TDI Westy
'90 Syncro 16 Doka

[thatvwbusguy]

You can get new crush washers thru McMaster Carr that might do the trick - http://www.mcmaster.com/#crush-washers/=c3cm3j

Probably the best move is to give Bostig a call or shoot them an email. I am sure they have a ready solution.
_________________
Jay Brown
'85 Zetec Westfalia
Newmarket, NH


If you want others to be happy, practice compassion.
If you want to be happy, practice compassion.

[John Sullivan]

Hey shooting fish, did you ever solve that PS leak problem on the Bostig. I have been living with a slight leak for a while. I removed the crush washers today and noted that the upper washer pump side is covering a concave port. The original Zetec ford PS hose is a pressure fitting not a banjo. The crush washer contours to that opening and apparently does not fully seal. I have weeping due to pressure when I shut off engine. No leak during run. I would appreciate your solution if you found one. I put new crush washers in today and still have the issue. I don't want to over torque the bolt.

[kourt]

I'll copy/paste something I put on the Bostig Zendesk forum a few years ago about this.

kourt

Well, I re-did the power steering setup again.

My chief complaint was the continued leakage from the original VW banjo fitting connected to the Zetec power steering pump. When you do a little investigation, one realizes that the pump's pressure port is designed for a special threaded fitting from Ford, not a banjo fitting.

Then you've got the ports on the steering rack itself, which are a special DIN fitting that can be found in the US, but not always easily.

Then you've got the OE reservoir and its nonstandard hose nipple ports (standard port sizes are 3/4" and 3/8").

I decided to nuke and pave, and move all connections to AN6 which is readily available in the US.

For the power steering pump, the pressure port can be converted to AN6 with the Massive Speed System AN6 model 9690 adapter.

The 3/4" nipple return port from the power steering pump can't be replaced, so we'll keep that for now.

Next, the steering rack. Removing all fittings, you are left with M14 x 1.5 for the pressure side and M16 x 1.5 for the return side. Convert these to AN6 with the Borgeson 925120 power steering adapters. They are steel and have an o-ring/washer sealing system.

For the reservoir, use the Cardone Service Plus 3R-701 reservoir, which has downward ports (3/4" and 3/8" nipple) and slips perfectly and tightly into the Bostig aluminum reservoir bracket. This is what I'm using right now. It lacks a dipstick in the cap, but it's otherwise a good budget deal that neatly fits the Bostig bracket.

Going to Parker hose, I had them build two 3/8" ID 3000PSI rated hoses with AN6 connectors on both ends, 13.5' long. One AN6 is 90 degrees (for the PS pump) and the other is straight (for the rack). One hose is for the pressure side, obviously using AN fittings. The other hose is for the return side. If you use the Cardone reservoir, get the return hose built with an undressed end and slip it on the 3/8" return nipple on the reservoir.

For the 3/4" return line from the reservoir to the PS pump, I used Gates 349990 Power Steering return hose, which is rated for the fluid.

The result is no more leaks. Wish I had done this earlier.

[John Sullivan]

Kourt, I like your idea. Since I replaced most of the hydraulic lines for steering previously with the exception of the banjo short hose. I am thinking to adapt your idea to apply to my set up. Based on your method, I will get the AN6 Massive adapter, and have a hose built with an AN6 90 degree on one end and a male mate to the 6G-10FDLORX (have to look that up) that I have on the long run to steering. I just have to measure the length of that short banjo hose.
This should eliminate the leak at the ford PS pump fitting. The Bostig crush washers into that ford fitting are just not getting it done for me. Thanks for the idea!

[jocoman]

This is a great idea! I live with a small leak at that connection and never knew that it is the wrong fitting!
_________________
'86 Westfalia 2.0L Zetec
'97 Volvo 850 AWD Turbo
" The fun never stops"

[John Sullivan]

I have almost finalized the replacement for the banjo hose to the Bostig PS. Keep in mind I have previously replaced the Hydraulic lines from the steering rack back to the banjo hose. The new lines use the 6G-10FDLORX mating to the existing cone VW short banjo hose The 6G-10FDLORX is a DIN 24* cone swivel with o-ring.
New hose:
The mate for above long high pressure hose is Gates 6G-10MDL, Male DIN 24* Cone. I ordered the Massive 9690 adapter from Massive, which is AN6 at the output. It turns out that the AN6 is not a typical Hydraulic house connection more of a MIL standard. But the AN6 is equal to and will mate to JIC-37*. I am going with a 90* fitting to mate with the 9690 adapter, This part is a JIC-37 flare swivel 90* bent tube, the fitting Gates 6G-6FJX90S My first measurement of the hose length is 25 inches (I want to recheck that again tomorrow, measure twice). I plan to use Gates 6M3K Hydraulic Hose, 3250 psi working pressure, with 2 in bend radius, 3/8 ID.

Result: 6G-10MDL -- 6M3K Hydraulic Hose -- 6G-6FJX90S and 9690 adapter

Plugging in the above into Biedler's Hydraulics gave a price of $62.15 plus shipping. Not bad! The massive adapter is about $17 plus shipping.

[kourt]

Glad this worked for you. When I made this change the engine bay stayed so much cleaner.

kourt