Replacing Power Steering Return Line

[Creekill]

I'm currently in the process of attempting to DIY a power steering cooler out of a general oil cooler that was supposed to be for another project. Im noticing that the earlier gen TJs may have return lines that connect to the rack and pinion with a simple hose clamp while the 2006 TJ I have uses some kind of metal hydraulic hose crimp fitting. I think its a barbed insert. I admit I'm not super educated with plumbing, so I'm learning as I go.

My understanding is that these metal hose parts are permanently crimped to the return hose and connect it to the rack and pinion. Would it be possible/safe to remove the whole metal hose piece and use some kind of other adapter and hose clamp? The hose I am hoping to use is coated with a nylon sleeve so I am wondering if a constant tension clamp would be sufficient.

I'm not looking to buy a dedicated PSC at the moment so I'm hoping to make do with what I have. I would seriously appreciate any suggestions on potential adapters or configurations that could potentially work.

 

[tworley]

No rack and pinion on TJ. There is a high pressure line from the pump to the steering gear, and a return line from the steering gear back to the pump.

Easiest way
https://blackmagicbrakes.com/ols/products/tj-machined-steering-cooler-wv-bar-bracket-stock-set-up-6

You can buy -6 an field serviceable fittings and hose.

 

[Creekill]

No rack and pinion on TJ. There is a high pressure line from the pump to the steering gear, and a return line from the steering gear back to the pump.

Easiest way
https://blackmagicbrakes.com/ols/products/tj-machined-steering-cooler-wv-bar-bracket-stock-set-up-6

You can buy -6 an field serviceable fittings and hose.

Thanks a ton for the advice! Apologies for the misunderstanding with the steering gear. I still got lots to learn with steering too since I haven’t ventured down that road much yet, either.

Since I’m not looking to spend a couple hundred on parts and just hoping to use what I have, do you think I could just cut the low pressure line and fit a -6 an to 3/8in adapter (like the one linked below) to attach the existing hose to the nylon hose that’ll lead to the cooler?

https://www.amazon.com/dp/B078BHNWZK?tag=wranglerorg-20

 

[hear]

The low pressure line already just hose clamps into the pump, right? I would expect that you would just instead route the return line from the gear to the input of the cooler. The fitting there will determine what you need, but it should be low pressure so I would expect that a hose clamp would be fine at all points along the return path.


If it starts spraying fluid, we'll know I was wrong. Happens all the time.

 

[mrblaine]

The low pressure line already just hose clamps into the pump, right?

Inlet nipple on the plastic reservoir in stock form. If you try to twist the hose off after you remove the clamp, 90% of the time the nipple goes with the hose. They break off very easily and the hose is bonded to it very well.

I would expect that you would just instead route the return line from the gear to the input of the cooler.

Correct, and then out of the cooler back to the inlet of the reservoir.

The fitting there will determine what you need, but it should be low pressure so I would expect that a hose clamp would be fine at all points along the return path.


If it starts spraying fluid, we'll know I was wrong. Happens all the time.

 

[Creekill]

The low pressure line already just hose clamps into the pump, right? I would expect that you would just instead route the return line from the gear to the input of the cooler. The fitting there will determine what you need, but it should be low pressure so I would expect that a hose clamp would be fine at all points along the return path.


If it starts spraying fluid, we'll know I was wrong. Happens all the time.

Haha! You know, I suppose that would be the most reasonable solution given the low pressure line is just connected to the pump with a clamp. Love to overthink these things. Thanks for the reply again! I’ll post an update here about what I do and how it turned out later