My return lines was corroded through and started to leak along the drivers frame rail. I have the old one removed, it came out in 2 pieces. Now I'm having trouble rerouting the hardlines between the frame and radiator. Has anyone here replaced theirs and how did you route it? At this point I'm ready to take off the front bumper to get more access.

Got a picture? If you’re referring to the “j” shape hardlines that hang low towards the front bumper, then you can replace them with a cooler and hoses. C4 sends a kit (derale) when you order their overland or hybrid bumper.

interesting. my 2012 is at toyota sitting on the lot waiting for a replacement return line from california... where did you source your parts from? I needed parts 4440660021 and 4441260430 but none available in Canada...

as for the reinstall it depends what section you are replacing. I think if you had a proper lift you could do it without removing the front bumper. or a second set of hands.

edit: mine was also leaking on the same spot as yours. all down the drivers frame rail, into the skid plate all around the sway bar

My 2011 just encountered this exact same problem today at 183,000 km. The low pressure power steering return line failed/leaked due to deterioration/corrosion.

My 4Runner gave a nasty groan pulling out of the driveway this morning when I was turning the front wheels to get on the roadway. I then noticed two small spots of fluid in my parking spot and knew right away that something was wrong with the power steering.

Straight to my mechanic I went!

Instead of ordering/waiting for OEM Toyota formed lines, the shop I take my 4Runner to custom fabricates the lines in-house from copper nickel (or cupro-nickel) 3/8 inch tubing.

They have also used similar cupro-nickel lines when previously repairing my leaking brake lines when they failed due to corrosion.