Power Steering Leak...lower return line

I know this was posted a few years ago, but hoping someone who did this line replacement can still help. How did you drain the PS fluid without (if possible) making a huge mess. I need to do this replacement but most of the info I've found deals with flushing the PS fluid. Thanks for any suggestions!
 
Reviving this old thread. I have a leak in my power steering hose and ordered the Rockauto new hoses. Looking for any extra tips to help with removal and replacement. Seems like the pump and rack do not have to be removed but removal may make installing the lines easier? Any tips from people who have completed this replacement would be much appreciated

Thanks!
 
Reviving this old thread. I have a leak in my power steering hose and ordered the Rockauto new hoses. Looking for any extra tips to help with removal and replacement. Seems like the pump and rack do not have to be removed but removal may make installing the lines easier? Any tips from people who have completed this replacement would be much appreciated

Thanks!

I can't really answer your question about removing the pump but I do know that removing the rack is a major job so I wouldn't even think about removing the rack.
 
I can't really answer your question about removing the pump but I do know that removing the rack is a major job so I wouldn't even think about removing the rack.

Thanks! After more research and time under the truck it looks like just the hard portion of the return line is slowly leaking. I have the high pressue line and return coming later this week and have used easy seal tape to wrap the entire metal line, seems like it has temporarily stopped the leak and hoping it will hold until the parts arrive
 
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.

Any idea what size the flange nut on the hard line is? I found somewhere that referenced a 17mm but just wanted to confirm i had the correct size line wrenches to get the job done

Thanks!
 
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..?

Hi I am new to the forum how, I was thinking of replacing the PS hoses as well, how are the SUNSONG 3401237 hoses holding up any update would be much appreciated. Thanks in advance.
 
Not sure who you posted that for but just to clarify for anyone that may need this part, that part fits the 2005 and all other 4TH Gen year models V6 engines..but doesn't fit a 2005 nor other year models 4TH Gen V8s.

Here you can find a catalog in their website itself. It lists all the parts they manufacture, these are accurate, you can find the corresponding parts here.
 
Hi I am new to the forum how, I was thinking of replacing the PS hoses as well, how are the SUNSONG 3401237 hoses holding up any update would be much appreciated. Thanks in advance.

I ended up buying a used high pressure toyota OEM power steering line from ebay and a sunsong low pressure line.
The high pressure connection to the power steering rack is hard to get to. Was a pain in the arse to remove.
 
I ended up buying a used high pressure toyota OEM power steering line from ebay and a sunsong low pressure line.
The high pressure connection to the power steering rack is hard to get to. Was a pain in the arse to remove.

Mine aren’t leaking “yet”, but are very scaly, so I’d like to replace them before they blow out at an inopertune time. What did you need for tools? It seems very tight in that area! Are there any seals or anything at the ends, or are they just flared line type connections? When I did the steering rack in my old Explorer, there were little Teflon seal washers at the connectors. I had to use cats paw flare wrench ends to access those fittings because it was impossible to get a regular flare wrench in there.
 
Anyone who replace their high pressure line with the sunsong have an issue where the line did not screw all the way down into the rack? I tried by hand probably 4/5 times and was able to get about half way then it was too difficult so I went with a wrench after that but there are still threads showing. I buttoned everything up and have been monitoring it with no leaks but it seems a little concerning to have threads.
 
Just replaced/repaired the low pressure hose on my '03 V8 couple weeks ago.
Used two straight 3/8" barb connectors and a length of 3/8" hose. I connected between the two hoses where the multi-bent steel tube was on driver side on top of frame, replaced the hose clamp on the frame with one that would accommodate the 3/8" hose OD. So far, so good. My high pressure hose looks very rusty/crusty so probably not long. I think I'll try the Edelman from RockAuto for $152.
 
Looks like I have a PS leak as well, but I'm having difficulty identifying the line needed. Mine is a 2007 V8 4runner, Is this part correct:
SUNSONG 3401220 Power Steering Return Line Hose Assembly

jThbTPy


I was going to try the low pressure side first. That is the connection with the host clamp, correct?

Is there a tip for getting the pics to show? I see the IMG.link.IMG in the post.
 
Last edited:
Looks like I have a PS leak as well, but I'm having difficulty identifying the line needed. Mine is a 2007 V8 4runner, Is this part correct:
SUNSONG 3401220 Power Steering Return Line Hose Assembly

jThbTPy


I was going to try the low pressure side first. That is the connection with the host clamp, correct?

Is there a tip for getting the pics to show? I see the IMG.link.IMG in the post.

Yes, low pressure is clamped to top of frame rail on drivers side behind wheel.
 
I have an '08 V8 and have a leak in the metal line clamped to the top of the frame rail on driver's side. Getting a bit confused on the terminology (upper/lower, high pressure/low pressure, gear to cooler, etc.)

Is this the correct replacement part?

Amazon.com

Also at Rock:
More Information for SUNSONG 3401220

Looks like it. I didn't replace mine, I just cut out the leaking section and replaced with hose, no problems since.
 
To follow up on this, the part I mention above was the correct part number. Not easy on my vehicle due to limited space in the engine bay, rusty bolts, and super tight, firm hoses.
Difficulties in changing:
1) Rusty bolts. Both are 12 mm and the one on top of the frame rail required an extractor socket to remove. Neither was super-tight, thankfully.

2) Pulling the leaking line from the rubber hoses on each end. This was a major pain, made easier by cutting the line up to create "handles" on each end and using a heat gun to soften up the front rubber hose (couldn't get the heat gun into the engine bay to get to the other end, but brute force and patience eventually prevailed). I tried pulling the radiator hose in order to get more room but -it didn't give any more room at all, and -just made a big mess when the coolant leaked out.

3) Working the new line into position. I eventually won by feeding the line from the front and working up from the ground, then twisting it as needed to feed it through. The lines/cords on the other side will get in the way a bit which is where another set of eyes/hands from the top helps. I tried forever to feed it directly from the front inside the bumper and got nowhere.

Good luck, friends.
 
new lower return line leak driver side

To follow up on this, the part I mention above was the correct part number. Not easy on my vehicle due to limited space in the engine bay, rusty bolts, and super tight, firm hoses.
Difficulties in changing:
1) Rusty bolts. Both are 12 mm and the one on top of the frame rail required an extractor socket to remove. Neither was super-tight, thankfully.

2) Pulling the leaking line from the rubber hoses on each end. This was a major pain, made easier by cutting the line up to create "handles" on each end and using a heat gun to soften up the front rubber hose (couldn't get the heat gun into the engine bay to get to the other end, but brute force and patience eventually prevailed). I tried pulling the radiator hose in order to get more room but -it didn't give any more room at all, and -just made a big mess when the coolant leaked out.

3) Working the new line into position. I eventually won by feeding the line from the front and working up from the ground, then twisting it as needed to feed it through. The lines/cords on the other side will get in the way a bit which is where another set of eyes/hands from the top helps. I tried forever to feed it directly from the front inside the bumper and got nowhere.

Good luck, friends.

I installed the new lower return line and new air vacuum control. My only issue now is I can't get the driver side connection to quit leaking. Any suggestions. I wasn't sure where to post a question, kinda new to this.
Thanks,
Dena
 

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