Power Steering Hydraulic Knock (Replace Power Steering Return Hose) (Export)

Customers may comment on a knocking noise from the front of the vehicle when cornering on a rough surface or when encountering a road irregularity, such as lane markers during cornering. This condition is normally experienced at road speeds in excess of 10 km/h.

Note: The condition as described in this bulletin occurs only during turning maneuvers. Knock experienced during straight line driving is NOT due to this condition.

This condition may be caused by cavitation of the power steering oil due to steering impact experienced during cornering on a rough road surface.

This correction involves replacement of the current power steering return hose with integral crossover pipe to a revised power steering return hose, which eliminates the metal crossover pipe section. Refer to the installation instructions below.

For vehicles repaired under warranty, use:

Installation procedure for new P/N return line to address hydraulic steering knock.

The procedure below is to remove the existing return line and crossover pipe (shown in red below) and replace it with a one-piece return hose. This procedure can be performed with the rack in the vehicle, but the photos have been taken with the steering gear out of the vehicle for clarity.

1. Drain the power steering fluid per the directions in SI.
2. Remove the return line, disconnecting it from the steering rack port replicator and cooler.



3. Disconnect the return line fitting from the steering gear input shaft valve connection.

Warning:  Ensure absolute cleanliness of the steering gear port during the remainder of this procedure. Prevent entry of contaminants to the now-exposed port.




4. Cut the return pipe at the port replicator using a bolt cutter or similar tool and discard the removed section of return line.



5. Install the banjo fitting of the new return hose, P/N 92219047, taking care to install the washer as shown. Finger tighten only at this stage. DO NOT FULLY TIGHTEN.



6. Remove and discard the port replicator attaching bolt (shown by the arrow).



7. Line up the primary return hose bracket with the remote port bracket mounting stud on the gear as shown.



8. Install the new bolt and spacer as shown.

Tighten
Tighten the bolt to 9 N·m.




9. Install the clips (P/N 92221532) as shown over the new hose and remaining crossover pipe.



10. Tighten the banjo bolt to 54 N·m.
11. Install the unconnected end of the new return pipe to the power steering cooler following the instructions in SI.
12. Fill, bleed and check the system for leaks per SI.