It was a tight squeeze getting out of my parking space tonight, so had to use the steering on full lock for more than usual. Halfway through the manouvre, the steering went a bit noisy. Like I had air in the system. Got down the road and it was pretty loud whenever I turned the wheel slightly. Then it just got insanely loud, so I pulled her over. Hydraulic fluid bubbling out of the pressure line from the pump. Looks like it's the joint between the rubber hose and the hardline with banjo that joins to the pump. Anyway, walked to ASDA and bought some steering fluid (stroke of luck they had some!). Whacked a load in the nearly totally empty reservoir. Drove about half a mile and it went loud again. Guessing the air lock had been worked out, as the reservoir was full of bubbles! Anyway, filled the reservoir to the brim and drove the rest of the way home (1 mile) with no noises. So hopefully the pump has survived!

So yeah, looks like I need a new power steering pressure hose, P/N: 1J0422893GM I think. It would be the bloody long one wouldn't it! It's all one piece too. This one: http://www.ecstuning.com/Volkswagen-Golf_IV--1.8T/Steering/Lines/ES307909/

I got some pics on my phone of the offending line so will try to get them up too.

Not surprised really, as the steel ends on the hose are rusty as hell. Bit of a ticking time bomb really.

Anyone got a spare used one knocking about that I could buy please?! I'm car-less now :'(

This is where I think it's blown:

Here are some shots of the aftermath!

That banjo bolt looks rusty as hell. Joy. It looks like it could be the steel pipe that's ruptured due to massive corrosion.

If yours looks like mine, then chuck a bottle of PAS fluid in the boot just incase!

Edited 22 February, 201115 yr by Bodge

Man, that is rusty, where do you keep it, in the sea at night?

Yeah tell me about it! Blame the gritters!

The best price Skoda will do for me is £145 inc. vat for the hose/pipe.

Ouch!

Don't these use the green fluid if so asda don't sell it did you put pink in? Not good if you did....your pump will be shot.

Yeah it was pink, but I figured it was better than running it dry! It's only run 1.5miles on the pink stuff, so shouldn't have done any damage. I do have a bottle of the proper stuff, so when I change the hose I will drain the whole system a couple of times to get all the pink stuff out.

What's the pump issue with the pink stuff anyway? I'm going to remove the reservoir and drain it out fully too.

Wish I didn't have poxy power steering!

Anyone know where all the brackets are for this pipe? I know of one on the front of the gearbox, but wondering how hard the one to the side of the box will be to get at. I might start stripping it down during the week.

not to bad to change would advise new banjo washers for rack side and pump side

bracket at pump another just under starter if i remeber correctly and just a clip over box

not to bad to change would advise new banjo washers for rack side and pump side

bracket at pump another just under starter if i remeber correctly and just a clip over box

Yeah I'm getting 2 new banjo bolts and all new copper washers to go on.

I've been out tonight to see how much of job it is, and looks pretty straight forward if I can get the car on axle stands. There are only two brackets holding the hardline to the gearbox. One on the front of the gearbox (by the starter), and one underneath the gearbox in the outermost corner. So should be simple enough. They are those thin rubber lined metal wrap around brackets that can be opened up and removed.

It's just a shame the hose has to be so damn expensive! Sh** happens.....

Edited 22 February, 201115 yr by Bodge

Paint the new one with vaseline or waxoyl when done

Yeah it was pink, but I figured it was better than running it dry!

Yes most definitely. You don't really want any fluid pumps of any kind running dry if you can help it. Or more importantly, the steer box itself.

Well, ordered all the bits for the job now. Managed to get the hose for £134 in the end, so just went for it.

1J0 422 893 GM - power steering pressure hose

8E0 422 529 - M14x1.5 rack banjo bolt (contains a 1-way valve)

N 013 849 5 - 14x20mm rack washer (x2)

WHT 001 800 (1J0 422 269 C) - M16x1.5 pump banjo bolt (hollow head for pressure sensor)

N 013 848 7 - 16x22mm pump washer (x2)

All the bolts and washers were cheap, but it's still a damn expensive job!

Hopefully this info helps someone else out in the future.

Edited 28 February, 201115 yr by Bodge

Just a final update that I've now fixed it.

Everything at the pump end was easy to get at and replace. You can undo the sensor and banjo bolt from above, with a 22mm deep socket, a UJ and long extension. The banjo bolt at the rack was easy enough to get to using a long extension and 19mm flexi socket through the wheel arch. But direct access with hands to put the new bolt and 2 washers back in was a pain in the anus! Pretty tight and fiddly.

The front bracket was easy, just had to be careful not to bend the soft bracket. The side bracket was a disaster though! As I undid the bolt, half the aluminium lug on the gearbox casing just came away! Not impressed. I managed to assemble the clip and bolt back onto half the lug, but it was obviously loose, so out came the faithful zipties! Four zip ties later and it's pretty solid. A later fix might be to glue the lug back on with some serious adhesive.

Anyway, I drained the whole system and refilled with some fresh CHF-11S (the green stuff). Steering actually feels lighter now with the fresh fluid.

No leaks or noises, so looks like a success.

Apart from the fact that it rained on Saturday, and I had to lie on my back in a freezing cold puddle of water while working!