Power Steering Leak...lower return line

[MountainsRcalling]

Documenting this in the event that others have the same issue.

Walked outside a few mornings ago and discovered signs of a large leak under the front drivers side. Opened the hood and saw my power steering reservoir was empty. I refilled with appropriate ATF and tried to see where the leak was at. Due to some recent fun at the Rebelle Rally, everything underneath was covered in a mixture of power steering fluid and sand making it impossible to see the origin. Yesterday I finally had the chance to drop the skid plate and power wash the underneath to get a good look.

After cleaning the area with brake cleaner, and turning the wheel a few times, I have an obvious leak at the connection between the lower return hose (low pressure) and the power steering link assembly. I also have some pretty nasty corrosion on the high pressure hose.

I plan on replacing the hose and am ordering the following parts from the dealership so I can return what I don't use.

Lower Return Hose - Toyota (44406-35021)
Return Tube - Toyota (44416-60370)
Clamp - Toyota (90080-46355)
Running Board Bolt - Toyota (90080-10083) (replaces 91641-H0820)

I am also going to start looking for a good used Pressure Hose - 2006 Toyota 4Runner (4441035691) since the corrosion leads me to believe it's only a matter of time.

Assuming I can get the parts from the dealer today at a decent price, I plan on doing the install tomorrow and will post again. Please chime in with anything I have missed.

Picture 1 Before the engine was on, Picture 2 with engine on and after wheel had been turned a few times.

 

[jfry008]

Documenting this in the event that others have the same issue.

Walked outside a few mornings ago and discovered signs of a large leak under the front drivers side. Opened the hood and saw my power steering reservoir was empty. I refilled with appropriate ATF and tried to see where the leak was at. Due to some recent fun at the Rebelle Rally, everything underneath was covered in a mixture of power steering fluid and sand making it impossible to see the origin. Yesterday I finally had the chance to drop the skid plate and power wash the underneath to get a good look.

After cleaning the area with brake cleaner, and turning the wheel a few times, I have an obvious leak at the connection between the lower return hose (low pressure) and the power steering link assembly. I also have some pretty nasty corrosion on the high pressure hose.

I plan on replacing the hose and am ordering the following parts from the dealership so I can return what I don't use.

Lower Return Hose - Toyota (44406-35021)
Return Tube - Toyota (44416-60370)
Clamp - Toyota (90080-46355)
Running Board Bolt - Toyota (90080-10083) (replaces 91641-H0820)

I am also going to start looking for a good used Pressure Hose - 2006 Toyota 4Runner (4441035691) since the corrosion leads me to believe it's only a matter of time.

Assuming I can get the parts from the dealer today at a decent price, I plan on doing the install tomorrow and will post again. Please chime in with anything I have missed.

Picture 1 Before the engine was on, Picture 2 with engine on and after wheel had been turned a few times.

SUNSONG 3401237, this is a cheaper alternative to Toyota 4441035691.
It can be found on rockauto. $85 VS $258. Both parts include the high pressure line and low pressure line.

I ordered 44406-35021 and it wasn't what I needed for my 08' V6..maybe it fits the V8..?

 

[ShutterTramping]

SUNSONG 3401237, this is a cheaper alternative to Toyota 4441035691.
It can be found on rockauto. $85 VS $258. Both parts include the high pressure line and low pressure line.

I ordered 44406-35021 and it wasn't what I needed for my 08' V6..maybe it fits the V8..?

Awesome, thanks. This is why I love this forum.

Sent from my SM-G900V using Tapatalk

 

[MountainsRcalling]

UPDATE to leaking power steering return line

UPDATE: I have been traveling an insane amount since posting this and finally got around to fixing it yesterday. Between the first post and yesterday, I had it checked out at the dealership to confirm the issue and also confirm a rear main seal leak (another story). The dealer diagnosed the issue as a leaking power steering rack and pinion and offered to fix it for the low low price of...wait for it...$2325.

Since the leak appeared to be at the upper portion of the hose near the clamp, rather than at the box, I decided to try to remove the hose, cut off the bottom inch and then re-attach it. Nothing to lose right?

Using these two tools (see image), I removed the clamp and then the hose. After examining the hose, it seemed intact but had hardened at the ends(age?).

My guess is that the stock spring clamp no longer had the force to effectively seal the hose. I replaced the hose with a fresh hose clamp and use a ratchet to tighten it up. Yesterday I drove for several hours on it with no leakage detected. This morning after a cold night, I checked again and there were no signs of a leak. If it does fail, I will update the issue here, but for now this is a great short term fix.

Eventually I will order the SUNSONG 3401237 as suggested and replace the whole thing, but not until it gets a lot warmer out!

 

[Timph003]

Power steering wheel fluid leaking

I just also discovered the power steering fluid leak, took the 4Runner to the dealer for diagnosis and it will cost almost $700 to fix the leak that includes parts and labor. Both of my upper and lower return hoses for the power steering pump are leaking.

I am thinking just to replace the rubber hoses and using the new hose clamps to see if that would stop the leaks. If I order the whole assembly for both upper and lower return hoses will cost around $200. Any advice on this issue would be greatly appreciated.

 

[Inv4drZm]

I just also discovered the power steering fluid leak, took the 4Runner to the dealer for diagnosis and it will cost almost $700 to fix the leak that includes parts and labor. Both of my upper and lower return hoses for the power steering pump are leaking.

I am thinking just to replace the rubber hoses and using the new hose clamps to see if that would stop the leaks. If I order the whole assembly for both upper and lower return hoses will cost around $200. Any advice on this issue would be greatly appreciated.

I had a leak exactly like in that picture. I just replaced the hose with one I had laying around because the old one looked like it had a bunch of little cracks in it. Hasn't leaked again for a month since, it was basically a free fix, and changed out the PS fluid at the same time.

 

[Timph003]

I had a leak exactly like in that picture. I just replaced the hose with one I had laying around because the old one looked like it had a bunch of little cracks in it. Hasn't leaked again for a month since, it was basically a free fix, and changed out the PS fluid at the same time.

Glad to hear this! Do you remember what are the dimensions of the hose? I might have just to take the hose off and bring it with me to the automotive store to see if they match one for me.

I could not take the picture of the upper return hose that connected to the rack and it looks like a PITA to get to it.

 

[Inv4drZm]

Glad to hear this! Do you remember what are the dimensions of the hose? I might have just to take the hose off and bring it with me to the automotive store to see if they match one for me.

I could not take the picture of the upper return hose that connected to the rack and it looks like a PITA to get to it.

Never measured it, just one that was laying around and it was an exact fit, so I assume it was a "standard" size. Cut the replacement an inch longer than you measure and lube the barb fittings before trying the stretch the hose over.

 

[Timph003]

Never measured it, just one that was laying around and it was an exact fit, so I assume it was a "standard" size. Cut the replacement an inch longer than you measure and lube the barb fittings before trying the stretch the hose over.

Ok, thanks for the advice.

 

[MountainsRcalling]

For about $90 (includes shipping) from Rock Auto you can pick up a SUNSONG 3401237 replacement for all the hoses as originally suggested by jfry008. If you are going to buy new hoses, this seems like the best way to go.

I just also discovered the power steering fluid leak, took the 4Runner to the dealer for diagnosis and it will cost almost $700 to fix the leak that includes parts and labor. Both of my upper and lower return hoses for the power steering pump are leaking.

I am thinking just to replace the rubber hoses and using the new hose clamps to see if that would stop the leaks. If I order the whole assembly for both upper and lower return hoses will cost around $200. Any advice on this issue would be greatly appreciated.

 

[Timph003]

Fixed the power steering fluid leaks

Hi all,

I was able to fixed all 3 power steering fluid leaks today, I replaced all the rubber hoses and clamps with the new ones bought from Napa. Got 3 feet of the return hoses for the P.S wheel, I did not know there are differences between fuel line hose and heater hose, P.S wheel hose and etc... so make sure you are getting the correct hose for different application. Hoses, clamps, p.s wheel fluid come out about $25 plus my labor, I just saved $675 from the STEALERSHIP.

I got panicked and went to the STEALER because of the heavy leak from return line from the rack, and was not sure where was the fluid come from. The nice thing about it they did not charge me anything for checking the leaks. They quoted me almost $700 for parts and labor to fix the leaks (check out my post on top for the parts that they recommended).

The hardest part is to replace the rubber hose from the rack, I have to come from the bottom to be able to reach it and could not find anyway to take the picture of it to show your guys. The 2 rubber hoses in the front bumper are easy to get to, check out my uploaded pictures.

I drove my 4Runner for more than an hour afterward and there is no more leak from all 3 different locations. I am far away from being a mechanic and was able to accomplish this job so I would think anyone should be able do this job. Stay away from the STEALER for this job, they will try to sell us the crapp that we don't need, I understand that everyone needs to make a living but don't put everything on me or sell me the crapp that I don't need. Send me an IM if you have any questions about this job.

Passengers side



Drivers side

 

[alia176]

Maybe I missed it but will this work on a V8 as well?

 

[Timph003]

Maybe I missed it but will this work on a V8 as well?

Yes definitely because my 4Runner is V8. The inlet diameter for the rubber hose for my return P.S fluid and is 3/8".

 

[AuSeeker]

Maybe I missed it but will this work on a V8 as well?

If you have leak in the rubber hoses on the low pressure line/s, then yes it will work. but if your leak is on the high pressure line you will need the complete replacement part/line, which you can get from Rockauto much cheaper than from the dealer.

Looking at both lines from Rockauto, there seems to be different lines for the V6 and the V8 high pressure lines, so they must be routed differently, but for the low pressure line there's no need for replacing the complete line, i.e. the rubber and metal sections, just replace the rubber sections and use new hose clamps, just make sure when replacing the rubber hoses they aren't pressing up against any metal which will wear the hose out from rubbing.

 

[banilla16]

If you have leak in the rubber hoses on the low pressure line/s, then yes it will work. but if your leak is on the high pressure line you will need the complete replacement part/line, which you can get from Rockauto much cheaper than from the dealer.

Looking at both lines from Rockauto, there seems to be different lines for the V6 and the V8 high pressure lines, so they must be routed differently, but for the low pressure line there's no need for replacing the complete line, i.e. the rubber and metal sections, just replace the rubber sections and use new hose clamps, just make sure when replacing the rubber hoses they aren't pressing up against any metal which will wear the hose out from rubbing.

looks like I'll be doing this sometime soon.... I have the driver side leak that has been slowly progressing over the last few months. I think a complete replacement will be the better way to go.

What did you use to replace the PS fluid?

 

[AuSeeker]

looks like I'll be doing this sometime soon.... I have the driver side leak that has been slowly progressing over the last few months. I think a complete replacement will be the better way to go.

What did you use to replace the PS fluid?

Use the same WS transmisson fluid that's used for the transmission.

 

[jfry008]

looks like I'll be doing this sometime soon.... I have the driver side leak that has been slowly progressing over the last few months. I think a complete replacement will be the better way to go.

What did you use to replace the PS fluid?

Use the same WS transmisson fluid that's used for the transmission.

The back of my owners manual calls for any dexron II or III ATF fluid for the
PS system...

 

[AuSeeker]

The back of my owners manual calls for any dexron II or III ATF fluid for the
PS system...

I used the WS because it's what I had left over from the transmission flush.

 

[Bilker]

Resurrecting this thread (I hope).

How do you access the bottom connections? I can barely see it from underneath. Any tips? I suspect the return line is leaking in my 2006 (V6) - but will replace both the pressure hose and return line using the more affordable SUNSONG option. Do I need to remove the radiator? It is possible to simply access it from underneath without removing anything but the skid plates?

I appreciate any tips you can give!

Thanks!

 

[drbyrdman]

Do they have a kit for a 2005 v8 sport 2wd?