How to fix pinhole leak in Al power steering line..

Buckgnarly · Sep 23, 2015

2004 Ranger power steering cooler line (fat Al line on low pressure side) has a pinhole leak from rubbing, 114 new from dealer. I'd rather fix the pinhole, what is my best bet?...solder, braze?....tips?

cowboy73 · Sep 23, 2015

I'd probably get one from a junkyard for $20. If it's the pressure line, it would be hard to get a good enough seal on that thin of aluminum. I had one leaking on a 2002 Buick. A new line was $238!!!!!! I went to the Pic-A-Part and got one for 20 bucks.

Colin HD · Sep 23, 2015

For a quick 'redneck' fix: small self tapping screw and some sealant!
For a real 'dealer' fix: remove & solder.

Buckgnarly · Sep 23, 2015

It's low pressure, it's already out, I was thinking solder but have never soldered anything like this.

LandofRath · Sep 23, 2015

Might be able to use alumaweld.. But I would just replace or depending on size and fitting just make a new one.

lilredex · Sep 23, 2015

Steel....braze it shut.

Aluminum.....cut a small rubber patch and hold it there with a hose clamp.

Look for a j/y replacement for the future.

Lotek · Sep 23, 2015

If you can't find one in a junkyard, that $114 is going to look pretty cheap when your mickey mouse repair blows out at 10pm in the rain... When it's worn like that, any attempt to solder the worn area will make the hole bigger, even if you can get aluminum solder to stick, what with the area being contaminated with p/s fluid, it will be weaker than the base metal, so that when it fails... A radiator shop might be able to clean and patch it, but you would be looking at similar money probably.

sberry · Sep 23, 2015

JB weld, any other thing is likely to damage it.

LEVE · Sep 23, 2015

I'd also add that if you do plug the line, be prepared to do the repair a second time. If it has a pinhole, there's likely more to follow that you may be missing and getting ready to burst.

Colin HD · Sep 23, 2015

It all depends if you need a 'get me home' fix or not!
Replacement is the way to go, if its your daily driver and you are keeping the car.

racingtadpole · Sep 23, 2015

Depending on the thickness of the tube you might be able to cut the leaking section out and fit something like this

http://hydraulicmegastore.com/light-series-straight-tube-to-tube-connectors.html

Ponchoguy · Sep 23, 2015

Lotek said:
If you can't find one in a junkyard, that $114 is going to look pretty cheap when your mickey mouse repair blows out at 10pm in the rain... When it's worn like that, any attempt to solder the worn area will make the hole bigger, even if you can get aluminum solder to stick, what with the area being contaminated with p/s fluid, it will be weaker than the base metal, so that when it fails... A radiator shop might be able to clean and patch it, but you would be looking at similar money probably.

Did you also check to see if Edelmann, Omega and the other PS hose manufacturers make a replacement?

jwith68 · Sep 23, 2015

If its a rubbed pinhole in the low pressure side, a brazing rod for aluminum repair will probably work fine to fix it. Look at Aladdin 3-in-1, or Durafix. De-contaminating the repair area will be key. All the PS fluid will need to be gone from the repair area. Get a small, brand new stainless steel wire brush and follow the cleaning instructions that come with the rod. It will be a process of heat, brush, heat, brush, braze, brush, etc. Build thickness, don't worry about making it look pretty.

These rods are regularly used to fix damaged A/C and refrigeration aluminum evaporator coils with good (but not 100%) success. The system pressures would be similar between the return side of a PS system and medium temp refrigeration evaporators.

mikebramel · Sep 23, 2015

Rescue Tape

mark18mwm · Sep 23, 2015

Buckgnarly said:
2004 Ranger power steering cooler line (fat Al line on low pressure side) has a pinhole leak from rubbing, 114 new from dealer. I'd rather fix the pinhole, what is my best bet?...solder, braze?....tips?

The dealer is always overpriced. Go to a regular parts store Orileys, Napa, Carquest etc. I don't know the specs on your ranger but I just looked up 04 Ranger with a v-6 and return line was about $12 and pressure line was $39. you can't cobble it for that price.

Flivver250 · Sep 23, 2015

Replace it. Why take a risk with steering or brakes? You could hurt someone. Not worth it. Fix it right and forget about it.

Buckgnarly · Sep 23, 2015

mark18mwm said:
The dealer is always overpriced. Go to a regular parts store Orileys, Napa, Carquest etc. I don't know the specs on your ranger but I just looked up 04 Ranger with a v-6 and return line was about $12 and pressure line was $39. you can't cobble it for that price.

Cannot find the cooling line, the one listed is the hard/soft return that comes out of the rack...the cooling line is a fat two turn coil that is tied in between the rack return and reservoir. Going to try NAPA and the JY when I get a chance later today.

Buckgnarly · Sep 23, 2015

Flivver250 said:
Replace it. Why take a risk with steering or brakes? You could hurt someone. Not worth it. Fix it right and forget about it.

Steering still works w/o power steering... :thumbup:

WhiffySpark · Sep 23, 2015

Buckgnarly said:
Steering still works w/o power steering...

For some people :lol_hitti

CJM8515 · Sep 23, 2015

Me, if I didnt AL solder it Id use JB weld. Id clean it as much as possible. JB weld it and then take some fuel line hose and 2 clamps and put it over the repair.

Doc · Sep 23, 2015

racingtadpole said:
Depending on the thickness of the tube you might be able to cut the leaking section out and fit something like this

http://hydraulicmegastore.com/light-series-straight-tube-to-tube-connectors.html

This, Cut the tubing right on the pin hole then use a compression fitting. I did this on a daily driver years ago and still not leaking. You can get them at any home depot/lowe/ ace etc.....

If you want even easier. cut the tubing and put a piece of hydraulic hose splicing the 2 together with worm clamps. Do this all the time for adding new transmission coolers.

stikman56 · Sep 23, 2015

I just bought new pressure line off ebay for 12 dollars shipped. They're between 18 and 28 bucks shipped, depending on what engine etc, you have.

Lotek · Sep 23, 2015

Doc said:
This, Cut the tubing right on the pin hole then use a compression fitting. I did this on a daily driver years ago and still not leaking. You can get them at any home depot/lowe/ ace etc.....

If you want even easier. cut the tubing and put a piece of hydraulic hose splicing the 2 together with worm clamps. Do this all the time for adding new transmission coolers.

You will want to put a bit of a flare in the ends to keep the line from working it's way off over time.
Then again, since the hole was caused by chafing, I'm thinking that it's a pretty tight spot, and there isn't going to be a lot of room for this. :dunno:

Ponchoguy · Sep 23, 2015

Buckgnarly said:
Cannot find the cooling line, the one listed is the hard/soft return that comes out of the rack...the cooling line is a fat two turn coil that is tied in between the rack return and reservoir. Going to try NAPA and the JY when I get a chance later today.

Call each company's tech line to be sure. Sometimes they don't realize that they actually have the part. Gates didn't realize that they had the fitted heated hoses for my '89 Cavalier, until I gave them the GM part #s and crossed them over and explained that they were missing a year out of their coverage.

They agreed and said, "We'll add it...and for the record, you're one of the few guys that finds mistakes in our catalogs and interchanges!!"

Buckgnarly · Sep 24, 2015

NAPA search even with Ford number came up empty, my usual JY was no luck as they just hack out racks and do not save the line, so off to the LWS. Guy gave me some Al rods that can be used for brazing, worked like a champ! Saved 80 bucks and learned to braze! :thumbup:

jwith68 · Sep 25, 2015

Buckgnarly said:
NAPA search even with Ford number came up empty, my usual JY was no luck as they just hack out racks and do not save the line, so off to the LWS. Guy gave me some Al rods that can be used for brazing, worked like a champ! Saved 80 bucks and learned to braze!

How to fix pinhole leak in Al power steering line..

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