Power Steering 101

Introduction to Power Steering

Introduction to Power Steering

Table of Contents
What is Power Steering? ....................................................................Page 2 Power Steering Systems.....................................................................Page 5 Power Steering Pumps......................................................................Page 10 Power Steering Hoses.......................................................................Page 11 Servicing Power Steering Systems ...................................................Page 12 Common Power Steering Malfunctions .............................................Page 13 Installation Procedure for Replacing Crimped or Ferruled Power Steering Return Line Assemblies..............................Page 14 Power Steering Belt Problems ..........................................................Page 15 Testing for Leaks ..............................................................................Page 16 How to Replace Power Steering Hose...............................................Page 17 Troubleshooting Power Steering Systems .........................................Page 19 Selling Power Steering Hose and Assemblies ...................................Page 21 Frequently Asked Questions or Problems..........................................Page 25 Level 101 Review Quiz......................................................................Page 27

What is Power Steering?

Power steering is a hydraulic system assisting the driver in turning the front wheels. The system usually consists of a hydraulic pump and fluid reservoir, a power-actuating mechanism such as a power cylinder, a control valve arrangement, and a series of flexible hydraulic hoses and couplings to route the hydraulic fluid under pressure. The pump derives power from the engine and is belt or gear driven.

Control Valve Rack & Pinion Power Steering Pulley Power Steering Pump

Power Steering Return Hose

Power Steering Pressure Hose

What is Power Steering?

The Development of Power Steering

The use of power steering in automotive vehicles dates back to 1925, when Vickers a Detroit pump manufacturer developed a power steering device similar to the linkage or booster-type we know today. In 1926, the Pierce Arrow offered power steering. Cadillac, in 1933, put power steering on its 12-cylinder models. As larger, heavier and faster vehicles were developed, steering systems were engineered for easier vehicle control. During the Depression years, power steering systems were temporarily shelved by most car manufacturers. People bought fewer cars and those they did buy were fairly utilitarian, with little demand for luxury. The war years also saw a lull in the development of power steering for passenger cars. However, this was not so for heavy-duty vehicles such as those used by the military. In fact, millions of heavy-duty and hard-to-steer military vehicles were equipped with power steering during the 1940s. In the early 50s, power steering for passenger cars re-emerged when both Chrysler and General Motors introduced it as an option on full-sized models. Following an initial surge in popularity, cars with power steering were not widely accepted. Many drivers tried power steering and believed it dangerous that it didnt allow a feel of the road. This negative reaction nearly disappeared as more and more drivers were exposed to power steering-equipped cars. Today, power steering is often considered a necessity.

What is Power Steering?

The Power Steering Market

Since model year 1962, over 225 million cars have been manufactured with power steering. Approximately 99 percent of U.S. vehicles currently are produced with power steering. Eighty-five percent of imports have power steering. Oddly enough, the increasing popularity of smaller compact and subcompact cars has not decreased the production of power steering equipment. You might think that these smaller cars do not need power steeringuntil you try to park one. This is because the engine and transmission weight on frontwheel drive vehicles makes them difficult to steer. All these figures add up to one thing: a tremendous market for power steering service and repair. The phenomenal growth in its popularity, ease of service, and high profit potential make power steering a market full of opportunities. Service stations and garages lose a substantial amount of business because of reluctance to service power steering systems. Some believe it takes special tools, complicated procedures and intensive training. This is simply not so. Most power steering problems are detected and solved with eyes and a set of basic wrenches.

99%

Vehicles equipped with power steering

What is Power Steering?

Power Steering Systems

Five main types of power steering systems on cars are: integral, rack and pinion, hydro-boost, linkage or booster, and remote reservoir.

Integral System
In this system, the power cylinder and control valve functions are combined into one unit located in the steering gearbox at the steering columns end. Here, a pressure flow director valve senses steering wheel movement and directs the fluid pressure to either side of a rack piston, which is directly geared to the pitman arm shaft. As the rack piston travels up or down under fluid pressure, the pitman shaft rotates, applying the needed boost to turn the wheels. The spent fluid is then re-circulated back to the pump reservoir. The integral system uses two or three hose assemblies: One pressure line from pump to steering gearbox. One or two return lines from steering gearbox back to pump or gear to reservoir and reservoir pump.

The Integral System uses two or three hose assemblies: one pressure line and one or two return lines.

The pressure line must withstand pressures ranging from 800 to 1,300 psi. The return line normally carries no more than 50 psi.

Pump

Fluid Reservoir Pressure Hose

Steering Gear

Return Hose Tie Rod

Flow Director Valve Rack Piston

Pitman Arm

Power Steering Systems

Power Assisted Rack and Pinion Steering System

Power assisted rack and pinion steering is commonly found on import cars and trucks and front wheel drive vehicles. When first introduced, it was commonly found on import cars and trucks. Today, its use is widespread and can be found on both domestic and import cars and trucks, and many sport utility vehicles. It is similar to the integral system because the power cylinder and the control valve are in the same housing. In rack and pinion steering, the gear on the steering columns end is similar to the pinion gear in the differential: cut on an angle, and meshed with a steel bar (the rack) toothed on one side. The rack is mounted parallel to the front axle and as the steering wheel turns, it operates directly on the tie rods without the use of a pitman arm, idler or intermediate (or relay) rod. Adding a power assist to this type of steering is quite simple. The power piston is actually part of the rack and the rack housing acts as the cylinder. The control valve is located in the pinion housing. Rotation of the steering shaft and pinion turns the valve to direct hydraulic pressure to either end of the rack piston.

Control Valve (in Pinion Housing) Housing

Pressure and Return

Rack
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Piston

Power Steering Systems

Hydro-Boost Brake System

On some late model cars and light trucks, there is an additional hydraulic system directly related to the power steering system that controls the cars power brake system. Called the hydro-boost system, it uses hydraulic pressure supplied by the power steering pump to actuate a brake booster. This is in contrast to the conventional vacuum-assist power brake system. The heart of the hydro-boost system is a valve controlling hydraulic pressure from the power steering pump and metering it to a brake boost pressure chamber connected to the brake master cylinder. The cars brake pedal movement actuates this system, providing a variable boost to the pedal force required to stop the car. A pressure hose connects the power steering pump to the hydro-boost assembly and from there to the power steering gear assembly. Return lines are routed to a manifold tee fitting and from there back to the power steering pump. Often the return lines are routed from the booster and gear directly to the pump. There are two pressure and two return lines.

Pressure Hose

Return Hose

Pressure Hose Power Steering Pump Master Brake Cylinder

Tee Manifold Return Hose Power Steering Gear Assembly

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Power Steering Systems

The Linkage (Booster) System

In the linkage system, the pump supplies hydraulic pressure to a control valve assembly attached to the pitman arm and intermediate rod. This control valve senses, by mechanical means, the steering wheel movement in either direction. The valve then directs the proper amount of hydraulic pressure to the power cylinder attached to the cars frame on one end and to the intermediate rod on the other. As fluid pressure is applied to either end of the power cylinder, it pushes or pulls the intermediate rod to affect the steering boost. The fluid is then re-directed back to the pump reservoir via the return hose line. The linkage system uses four hose assemblies: One pressure line from pump to control valve. Two cylinder lines from control valve to power cylinder. One return line from control valve back to the pump reservoir. The pressure and cylinder lines must withstand pressure ranging from 800 to 1,100 psi. The return line normally carries up to 40 psi. Under normal driving conditions, the pressure exerted in the power cylinder is about 100 psi. When turning corners, the pressure increases to 400 psi. Parking, the most demanding power steering activity, requires pressures between 900 and 1,100 psi. Pump Pump Pulley Return Hose

The Linkage System uses four hose assemblies: one pressure line, two cylinder lines and one return line.

Pressure Hose Pitman Arm Control Valve

Power Cylinder Pressure Hoses

Power Steering Systems

Remote Reservoir System

1 Pressure Hose Assembly 1 Return Hose Assembly 1 Reservoir Hose This system is common on many small, front wheel drive vehicles and vans. Car manufacturers use remote reservoirs to maximize space under the hood. Fluid is transported from reservoir to pump through the reservoir hose. The pump then supplies the pressure to transport fluid through the system and returns it to the remote reservoir.

Remote Reservoir

Reservoir Hose to Pump

The Remote Reservoir System is common on many small, frontwheel-drive vehicles and vans.

Return Line to Remote Reservoir Pump

Pressure Hose to Pump

Rack & Pinion Gear

Power Steering Systems

Power Steering Pumps

There are three types of power steering pumps: vane, roller and slipper. The vane type is the most popular. The difference between pumps used is the design of the fins that move the fluid within the pump to build pressure. All pumps use a rotor that spins inside the pump housing. With the vane type pump, the rotor turns inside an oval or elliptical housing. The vanes, fitted to the outside diameter of the rotor, ride against the housing walls as the rotor turns. Power steering fluid enters the oval housing and fluid is trapped between the vanes, housing wall and rotor. This causes a pressure increase that pumps fluid out of the housing through the outlet chambers. In roller type pumps, the housings inside contour is also oval. Wide V-grooves are cut into the rotor. Steel rollers ride in these grooves and, like the vane type, they follow the inside contour of the pump housing as centrifugal force pushes them out at the ovals end. The rollers trap fluid in the same way as the vanes and when they pass the narrow portions of the body, they pressurize the fluid and force it out through two outlets. Also rotating in an elliptical chamber within the pump body, the rotor of the slipper type pump has several wide slots cut into it fitted with springs topped by scrubber-type slippers. The springs keep the slippers in contact with the pump body walls. The whole assembly resembles a spring-loaded hone spinning within an engine cylinder.

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Power Steering Pumps

Power Steering Fluid

This fluid is a specially formulated solution. It may be similar to automatic transmission fluid and may contain some of the same rust and corrosion inhibitors, but it is not the same. Power steering fluid is made to withstand higher temperatures. Power steering fluid must also be compatible with the rubber materials in hoses, pump seals, valves and cylinders. Blended to resist thinning at high temperatures, it usually contains a pour point depressant to maintain flow at temperatures as low as -20 F. The power steering system must be filled to the proper level with clean fluid at all times to maintain precise steering action. The biggest enemy of power steering systems is dirt and sludge in the fluid.

Power Steering Hoses

As we have seen, hoses for power steering systems generally fall into three categories: pressure lines, return lines and cylinder lines. Cylinder lines are used on all late-model rack and pinion cars. Pressure lines are often subjected to hydraulic pressures of up to 1,300 psi. These hoses must be constructed differently from return lines, which rarely carry more than 50 psi. The purpose of power steering hoses is to transmit power by conducting fluid under pressure from the pump to the actuating mechanism and back to the pump. But these hoses must perform other jobs that are not so obvious. Power steering hoses also serve as reservoirs for fluid and act as sound and vibration dampers. Pressure hoses are subject to surges in pressures and pulsation from the pump. Consequently, these hoses must be slightly expandable to reduce or absorb fluctuations. Hoses must also withstand heat. During parking, for example, fluid temperatures often reach 300 F. It is important to remember that power steering hoses lose their effectiveness long before showing external signs of deterioration and leaking. In addition, hoses usually deteriorate from the inside first. High fluid temperatures and constant flexing cause particles of the hose interior to flake off and contaminate the system resulting in plugged strainers, sticking control valves and overall erratic system behavior.

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Power Steering Hoses

Servicing Power Steering Systems

The steady increase in number of vehicles equipped with power steering means a greater increase in power steering service business for garages and service stations. Trouble-shooting power steering systems protects customers from breakdown on the road and a simple courtesy check builds customer confidence and business. Checking power steering systems on a regular basis also means increasing sales not only in replacement hose but in related power steering parts and service, such as: fluid, belts, pumps, cylinder, front-end alignment parts, and steering gear service. The reason many service stations and garage owners have not realized more of this profitable service potential is that they think power steering systems are too complicated. They are apprehensive of tearing into something they cant fix. Here are some common myths and facts about power steering.

Myths
You have to be a factory-trained expert to work on power steering.

Facts
Power steering units arent difficult to service. The incidence of complete failure of power steering systems is very small. The greatest share of all power steering service is of the quick service type rather than the extensive overhaul. Most power steering troubles can be solved with a new hose, clean fluid, and a couple of wrenches. In most cases, the customer will help you spot the trouble. He will describe the sounds and feels which help you determine the areas to check. A basic knowledge of how power steering systems work is all that you need to provide an accurate diagnosis. All power steering malfunctions are repaired while the engine is off, when there is no pressure in the system. Most troubles are caused by leaking hoses, fittings, pump seals or oil reservoir gaskets, and broken or mis-adjusted pump drive belts. Repairs or adjustments to correct these problems are not complicated procedures.

You must have a lot of specialized tools to service power steering systems. You need special training to diagnose power steering problems.

Power steering systems operate under very high pressures and are dangerous to service.
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Power steering systems are too involved and technicians are hesitant to start something they possibly cant handle.

Servicing Power Steering Systems

Common Power Steering Malfunctions

Because of exposure to underhood heat, high fluid temperatures, ozone, flexing, abrasion, grease, oil and road salt, power steering hoses should be replaced at least every five years to ensure safe operation.

Common Problems With Power Steering Assemblies

When checking power steering hoses, watch for symptoms indicating the hose has deteriorated and should be replaced: Hose is brittle or hard. With age, the hose loses its ability to expand and contract properly, and cracks appear. Exposure to excess heat (which overcures the rubber compounds) can cause this. Hose is soft and spongy. A good sign that the hose has started to deteriorate inside. Oil and grease-soaked hoses are soft when squeezed, and should be replaced. Exterior is worn. Caused by abrasion and contact with metal parts, this can eventually wear a hole in the hose, causing it to burst under pressure. Remember that not all power steering hose failures can be spotted by exterior signs. Hose can deteriorate from the inside, causing small particles of the tube to flake off and be carried away by the fluid. These small particles can cause expensive damage to the pump, pump cylinder and other units. This composite illustration shows the many areas of deterioration that are easy to detect by an alert technician. If the hose is soft and spongy, internal deterioration is the problem. The conscientious technician suggests that power steering assemblies be replaced at regular intervals. After five years power steering hose assemblies should be replaced no matter how they look. This is just good maintenance.

Weeper

Ends Peeling Exterior Deterioration

Hose Peeling Off Due To Over-Crimped Fitting Wear From Rubbing Against Metal

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(Return Hose Line)

Split or Dent Checking Stripped Threads Coupling Creeping Off

Common Power Steering Malfunctions

Installation Procedure for Replacing Crimped or Ferruled Power Steering Return Line Assemblies
Note: This is ONLY for return line assemblies and will not work for pressure assemblies. 1. Locate the hose to be replaced. If possible, for easier access, remove assembly from vehicle. Locate the ferrule attaching hose to the assembly. 2. If assembly is removed from vehicle, clamp it with a vise or to a stationary object, such as a table. BE CAREFUL to not distort the assembly when clamping. 3. Using a hacksaw, dremmel tool or other cutting-type tool, carefully cut the ferrule lengthwiseslitting the ferrule from end to end. IMPORTANT: Cut only the ferrule. Cutting through the hose can damage the tube or nipple surface. Caution: Always wear eye protection when using a power tool.

4. After ferrule is split, spread it open and remove it from the assembly.

5. Remove ferrule and existing hose. If hose is stuck, do not force or pry it off. This could damage the nipple. Use a sharp knife to cut or peel it off. Dont cut too deep avoid scoring the tube/nipple surface.

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6. Check nipple for damage and clean nipple with a wire brush to assure a smooth sealing surface.

7. Install new hose and secure with new clamps. Lubricating hose with power steering fluid makes installation over nipple easier. Position new clamp over hose between raised bead and exposed tube surfaces. Tighten clamp to recommended specifications. 8. Reinstall assembly. With engine at operating temperature, check for leaks and tighten clamps as needed.
Installation Procedure

Power Steering Pump Problems

In general, power steering pumps give little trouble if the fluid is clean and the right type. The proper fluid level must be maintained and checked at every engine oil change or when apparent leaks are in the system. If there are leaks, they must be found and repaired with a Gates pump seal repair kit, if possible. At least every 10,000 miles, inspect the power steering fluid reservoir for dirt. First, shut off the engine, remove the filler cap or reservoir cover and, with your fingers, feel the reservoir for dirt, sludge or rubber particles. Pump and control valve problems are detected by erratic wheel movements when the engine is operating.

Power Steering Belt Problems

A worn or broken V-belt or V-ribbed belt may cause slipping. A slipping belt doesnt turn pulleys efficiently and overheats. An overheated belt can transfer its heat to the pulley and drive shaft and overheat the bearing lubricants, which can lead to accessory damage. The big damage, however, is that loose or lost belts can cause engines to overheat. Ideally, all drive belts should be inspected for wear and properly tensioned once a month. Today, wear on a bandless V-belt or V-ribbed belt is more difficult to detect an old belt can look about the same as a new one. Tests have shown the chance of belt failure on a non-timing belt drive goes up dramatically after the fourth year of service. Thats why we at Gates have been reminding consumers to replace their belts, regardless of how they look, every four years as the proper belt maintenance procedure. Cracks Deep bottom cracks that appear at regular intervals are caused by the belt turning around a too-small pulley (usually the alternator) the undercord is being stressed to the breaking point. Smaller, irregular cracks, however, usually just indicate a belt that has weathered a long life. Missing Chunks or Brittle, Separating Layers A belt that is falling apart in layers could be a victim of oil. Oil and grease are a rubber compounds worst enemies. Oils weaken the compounds bonds making the belt soft, spongy and considerably weaker. Eventually, such a belt will slip. These oils can come from belt dressings (which should never be used) or from leaking engine parts.

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Power Steering Belt Problems

Testing for Leaks

The power steering fluid must be at a normal operating temperature when tested for leaks. This can be done by running the engine with the tires on the ground and rotating the steering wheel from stop to stop left and right several times. The steering wheel should not be held in the extreme left or right position for more than a few seconds, as the system is under maximum strain in this situation. Most leaks in hoses, fittings or seals will spurt fluid when the system is operating. So, inspect for wet spots. If the leak involves a loose fitting, tighten it and add fluid. If the hose must be replaced, or new units installed, use clean, new fluid. Never reuse the old fluid. IMPORTANT: Power steering fluid under pressure even dripping from pinhole leaks can vaporize. This vaporized fluid is extremely flammable. For this reason, even the smallest leak is a potential fire hazard and should be immediately corrected.

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Testing for Leaks

How To Replace A Power Steering Hose

These instructions are NOT designed to cover individual applications. Each power steering system has different hose locations, routing and attachment points. Some Gates hose assemblies may not look exactly like the original hose. Routing may also be different. Gates recommends replacing return line hose when the pressure line hose is being replaced. CAUTION: To prevent accidental starting, shut off the engine and remove key from ignition. Before installing a hydro-boost hose assembly, pump the brake pedal several times to reduce system pressure. Hydro-boost systems are identified by power steering hose connected to the brake master cylinder.

1. System Inspection
First, examine all power steering hoses for wear. If one hose must be replaced, it is almost certain that all hoses should be. Concealed internal hose deterioration may result in small particles of rubber flaking off interior hose walls. These particles may then pass through the system and can subsequently block valving. Power steering fluid should also be examined. Dark, discolored and dirty fluid is an indication that all hoses need replacement. It also indicates that the power steering fluid should be replaced. When checking hoses for wear, look for the following: Leakage of power steering fluid near hose ends. Brittleness or hardness, a sign of internal wear. Soft or spongy hose, complete internal deterioration. External wear or abrasion from manifold or other engine parts.

2. How To Remove Your Old Hose

Use an open-end wrench, line wrench or screwdriver as required to remove old hose. Hold both ends of hose up when removing to prevent fluid spillage.

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How To Replace A Power Steering Hose

3. How to Install Your New Hose

Pressure Hose: (Hose with threaded end fittings.) Hand thread fittings. Finish tightening with open-end wrench or line wrench of the proper size. Go to step 4. Return Hose: (Hoses with clamped ends.) Connect end opposite pump only. If hose has threaded fitting, hand tighten and finish tightening with open-end wrench or line wrench. DO NOT OVERTIGHTEN. If hose has clamped connection, push hose over nipple and tighten using hose clamp suitable for hose. Go to step 4.

4. Flushing and Bleeding Instructions

A. Disconnect return line at pump end and place in drain pan. Cover tube on pump with flushing cap. B. Fill reservoir with recommended fluid. Start engine. C. Cycle steering wheel from side to side (fill reservoir as required) until fluid is clear. D. Stop engine. Remove flushing cap, connect return line hose and re-check fluid level.

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Caution: Extreme care must be taken to completely flush the system. Contaminated fluid will cause unsatisfactory performance.

How To Replace A Power Steering Hose

Troubleshooting Power Steering Systems

The complete breakdown of a power steering system can be costly to life and property. Many of us have had the experience of trying to control a power steering-equipped car with the engine off. The same difficulty occurs when the power steering system fails. Imagine what could happen on an icy road, in a high-speed turn, or if a front tire blows out. Most power steering malfunctions, however, are preceded by a noise or other condition thats a warning signal, such as a buzzing sound when turning sharply, or the steering wheel failing to return to the straight ahead position after a turn, or an increase in effort needed to turn the wheel. All should be a warning to alert the driver. When diagnosing power steering problems, check and adjust the related mechanical components first, such as wheel alignment, tire inflation, proper lubrication and belt tension. If this doesnt correct the problem, then its time to investigate the power steering system itself.

Troubleshooting Guide
Heavy Steering Effort 1. Low on power steering fluid. 2. Loose rack piston. 3. Restricted fluid passages in gear assembly. 4. Bent or damaged rack assembly. 5. Internal fluid leakage in valve assembly. 6. External fluid leakage at pump. 7. Incorrect drive belt tension. 8. External fluid leakage at hoses. 9. Incorrect engine idle speed. 10. Weak pump flow pressure. 1. Internal leakage in steering gear. 2. Steering wheel at end of travel (normal). 3. When turning steering wheel at standstill (normal).
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Hissing Noise When Parking

Growl in Steering Pump

1. Excessive pressure in hoses. 2. Worn cam ring in pump. 3. Scored thrust plates or rotor in pump. 4. Scored pressure plates. 1. Defective flow control valve.
continues next page

Swish Noise in Pump

Troubleshooting Power Steering Systems

Troubleshooting Guide
Whine in Pump 1. Air in power steering fluid. 2. Low power steering fluid level. 3. Pressure hose or line contacting other part. 4. Mis-aligned hose and line brackets. 5. Missing or damaged pump cover O-ring. 1. Pressure hose contacting another part. 2. Loose pitman shaft. 3. Lost pitman arm. 4. Loose tie rod ends. 5. Loose rack and pinion mounts. 6. Loose steering gear housing bolts. 7. Loose steering gear adjustments. 1. Incorrect front wheel alignment. 2. Unbalanced steering gear valve. 3. Loose tie rod ends. 1. Low power steering fluid level. 2. Loose pump drive belt. 3. Weak pump pressure. 4. Sticking flow control valve. 1. Air in hydraulic system. 2. Incorrect steering gear adjustments. 3. Loose steering gear coupling. 4. Loose steering shaft universal joint. 5. Faulty rotary valve. 1. Slipping pump drive belt. 2. Internal pump leakage. 3. Low power steering fluid level. 4. Too low engine idle speed. 5. Air in hydraulic system. 6. Weak pump output. 7. Malfunctioning steering gear. 1. Maladjusted steering wheel. 2. Dry ball joints or linkage joints. 3. Binding ball joints or linkage joints. 4. Incorrect front wheel alignment. 5. Maladjusted wheel bearings. 6. Kinked return hoses. 7. Internal pump leakage. 8. Contaminated power steering fluid. 9. Mis-aligned steering gear-to-steering column. 10. Tight steering shaft bearings or bushings. 11. Bent or damaged rack. 12. Sticking or plugged spool valve.

Rattle in Steering

Car Wanders to One Side

Steering Wheel Surges or Jerks

Excessive Play in Steering Wheel

Increased Steering Effort on Fast Turn

Poor Return of Steering Wheel

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Troubleshooting Power Steering Systems

Selling Power Steering Hose and Assemblies

The market for power steering replacement hoses and assemblies is extensive and continues to grow every year. As more and more new cars are built with power steering as original equipment, an increasing number of your customers will need power steering service. It does not take special training or sophisticated tools to work on power steering systems. In fact, these systems are no more complicated than most brake systems. Safety also plays a big part in selling power steering replacement parts. Your customers are buying security when you sell them new power steering hoses and fittings. Providing customers this vital and profitable service means you must stock a complete line of high-quality replacement hose, fittings and assemblies. Youll also want to deal with a hose and assembly manufacturer with the training, merchandising and technical support you need to take advantage of this profitable market. You want a line serviced by a factory representative. He will help promote power steering products at all levels of the distribution system warehouse, jobber and dealer. Now, lets look at a line of power steering hoses, fittings and assemblies that gives you all the advantages just mentioned.

The Gates Power Steering Line

Gates has fully trained part researchers and ASE (Automotive Service Excellence) certified technicians. This ensures your Gates power steering hose fits your vehicles better than other manufacturers hose. Gates is the only power steering assembly supplier that manufactures both hose and fittingsresulting in better quality control. Gates power steering hose withstands oil temperatures of 300 F and the cover resists oil, heat and weather. The fittings are heavy-gauge, plated to resist corrosion and give maximum service. Couplings and fittings meet both SAE specifications and Gates rigid standards for excellence. Uniform crimping process ensures a long-lasting connection. Gates has been building power steering hose for the OEM market for over 25 years.
Selling Power Steering Hose and Assemblies 21

OEM-type Assemblies

Downsized engines prevent rerouting without safety hazards. Therefore, the trend is toward OEM assemblies because they are faster and easier to install and safer due to underhood congestion. Gates part numbers are consolidated whenever possible to reduce inventory but only when there is no compromise on fit or safety. Gates OEM return line assemblies come with both ends fitted with factory-installed, pre-bent end fittings or with a permanent end fitting on one end only. With the latter, the connection is made with an ordinary worm-drive clamp on the end without a fitting. NOTE: Bulk return line hose is also available for many applications. This hose, in 3/8", 11/32", 1/2", 5/8" and 3/4" I.D., is easily cut to size and connections on both ends are made with worm-drive clamps.

Power Steering Hose

Power steering hose is suitable for operating at a working pressure of 1,600 psi and in temperature extremes of 40 F to +300 F. It also must operate in systems where expansion under pressure is required to reduce its tendency to amplify the pump pressure pulsations. Power steering hoses are subjected to many hazards such as road debris, vibration, abrasion from moving parts and high ambient temperatures. To protect hose from these hazards, Gates uses convoluted and heat-resistant covers to provide the longest lasting hose in the industry. Gates power steering pressure hose has a double-rayon braid reinforcement cord designed to withstand pressure pulsations up to 6,400 pounds. The inner hose tube withstands oil temperatures of 300 F without deterioration. The cover of Gates power steering hose is highly resistant to oil, heat and weathering the external forces which tend to break down ordinary power steering hoses.

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Selling Power Steering Hose and Assemblies

To make sure Gates power steering hoses offer maximum safety and performance, an elaborate testing program is followed. Gates hose and assemblies are tested for: Volumetric Expansion Pressure is applied to the hose and maintained for a given period of time. The expansion is measured to ensure the hose design doesnt expand too much or too little. Bursting Strength Assemblies must meet a minimum bursting strength of 6,000 psi. Tensile Strength Assemblies must withstand a minimum tensile load without the fittings pulling off or the hose rupturing. Impulse Testing Oil, under varying pressures, is circulated through the hose to duplicate actual power steering operating conditions for a specific number of cycles.

Gates commitment to the installer is supported by a team of application research specialists who inspect each power steering application.

Low-Temperature Flexibility Sample hoses are subjected to -40 F and then flexed around a mandrel in a 180 bend. Ozone Resistance Sample hoses are placed in a special chamber and subjected to high ozone concentrations. The hoses are then flexed and inspected for cracks in the cover. As a result of these comprehensive, accelerated tests, you can safely assure your customers that Gates power steering hose is unsurpassed in performance and reliability.

Field Research
Gates commitment to the installer is supported by a team of application research specialists who inspect each power steering application. This team insures every Gates hose meets or exceeds the quality and fit of the OE hose. Due to the field research of this team, Gates hoses can be installed with confidence, knowing every switch port, bracket, and cover will be in place.
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Fittings
All metal parts used in Gates power steering hose assemblies are plated to resist corrosion and are made of heavy gauge materials for maximum service life. All Gates power steering couplings and fittings are manufactured under controlled conditions to assure proper fit. A uniform crimping process provides a strong, long-lasting connection. Fittings are subjected to stringent laboratory testing to assure compliance with all SAE specifications.
Selling Power Steering Hose and Assemblies

Power Steering Assemblies

Gates power steering assemblies are OEM-type hose assemblies. The ends of the ferrules are flared to prevent pinching or cutting the hose. Crimping pressure is equally distributed around the entire hose circumference, eliminating the hoses tendency to roll or twist. Sealing lands are used on the inside of the crimped collar as well as on the inserts the hose slips over. When you compare product line, coverage, manpower assistance and technical know-how, Gates power steering line has a decided edge over the competition. And, the information in this manual makes it easy to handle and sell Gates, the premium power steering line.

Repair Kits
Gates offers a full line of power steering repair kits for pumps, rack and pinions, and gears. Gates kits include all necessary seals and hardware to rebuild your power steering product to original or better-thanoriginal standards. Why use Gates Power Steering Repair Kits? Because every Gates kit is packaged with original equipment-quality components to guarantee that you only have to do the job once. And, with the detailed instruction sheets included with the kit, you have all the information you need to do the job right. Repair kits offer an economical alternative to replacing the entire unit, as well. Many of the repair jobs can be performed on the car, without having to remove the unit. And the repair kit is much lower in price than buying a new or even a remanufactured unit.
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Selling Power Steering Hose and Assemblies

Frequently Asked Questions or Problems

Problem: I bought a seal kit for my Saginaw steering gear and the input shaft seals are too big (or too small). What do I do? Solution: In 1979, Saginaw went from a large input shaft (7/8), known as the First Design, to a small input shaft (3/4) called the Second Design. However, not all users of the gear changed over at the same time since they needed to use up any existing stocks on hand. And there are a lot of remanufactured and used units that may have been swapped around since the gear housings themselves didnt change. If the seals you have in your kit are too large, youve got a Second Design gear. Use kit numbers 351300/351320. If the seals are too small, youve got the First Design. Use kit numbers 351120/351310.

Problem: My GM vehicle has a small pump with a plastic reservoir. I know its either a TC or CB pump but I dont know which. How do I tell? Solution: If the pump is still on the vehicle, measure the O.D. of the pump shaft. If its 16.9 millimeters, its a TC pump. If it measures 19mm, its a CB pump. If the pump is off the vehicle or already apart, another easy way to tell is if the pump had a bearing in front of the seal and a smaller bearing in the rear housing. In that case, its a TC pump. The CB pump uses a bushing instead.

Problem: I bought an adjuster plug seal kit to cure the leak by the adjuster nut on my pitman shaft. Nothing is right! Solution: If youll look in the repair kit section of the Power Steering catalog #31-2140, youll see what we mean by adjuster plug. This area of a steering gear goes by several names: input shaft, stub shaft, worm, adjuster plug. We are using the Saginaw term for this part of the gear.

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Frequently Asked Questions or Problems

Problem: I tried to put the plastic ring on my gear piston (or valve). It stretched and wont fit. Why? What do I do? Solution: This plastic ring is actually made of Teflon. Most service manuals give specific instructions on how to install these properly. It requires special expanding and resizing tools. If you dont have access to the tools or just like doing things the hard way, you might try boiling the ring for about ten minutes and installing it while its still VERY HOT! This will usually let the plastic filler expand enough to go on and then it will contract a bit when it cools. There are no guarantees with this procedure, though; we always stress the use of the correct tools and proper service manuals and procedures for any job, especially one that is as safety-related as this.

Problem: I went to put a pitman shaft seal kit into my 1976 Ford gear. Two oil seals came out but the new kit only has one. Why? Solution: Actually, the new kit matches what Ford is selling now. And it even makes sense. They made this change to relocate the area where the sealing lip contacts the shaft. After several years, the lip wears a spot on the shaft and putting a new seal on this worn spot doesnt do a whole lot of good. The new seal pack fits and is identical to the original equipment.

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Frequently Asked Questions or Problems

Level 101 Review Quiz

1. List three components used in the power steering system. a. b. c. 2. What is the primary purpose of the power steering system? 3. The _____ derives power from the ______ and is _____ or gear driven. 4. What are the five main types of power steering systems on cars? a. b. c. d. e. 5. How many hoses does an integral system use? a. one b. two c. two or three d. none of the above

6. The pressure line must withstand pressures ranging from 800 to 1,300 psi. True or False? 7. Power-assisted rack and pinion steering systems are commonly found on rear-wheel drive vehicles. True or False? 8. The hydro-boost system controls the vehicles a. fuel system b. power brake system c. air conditioning system d. none of the above 9. Which system is common on small, front-wheel-drive vehicles and vans? a. remote reservoir systems b. linkage (booster) systems c. hydro-boost brake systems 10. The biggest enemies of power steering system fluid are a. b.
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Level 101 Review Quiz

11. Name the three types of power steering hoses. a. c. 12. The purpose of a power steering hose is to transmit power. True or False? 13. Power steering hoses deteriorate from the inside first. True or False? 14. Power steering hoses must meet a minimum bursting strength of: a. 1,300 psi b. 50 psi c. 6,000 psi d. none of the above 15. Gates complete line of power steering hose assemblies looks and feels like the ___________. 16. Gates offers a full line of power steering repair kits for: a. b. c. 17. Every Gates repair kit is packaged with: a. b. 18. Power steering repair kits offer an ___________ alternative to replacing the entire power steering pump. 19. What is the distinctive mark used on Gates pressure and cylinder line hoses? 20. Fill in the blanks below with the related item.
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a. switch sockets b. tearn-coated tubes c. restrictors d. silver heat guard e. split conduit hose f. double lock beading g. braze on/or moveable brackets h. end lock tabs

___ prevents hose end from loosening ___ absorbs vibration and reduces noise ___ protects hose in high heat areas ___ allows easy and secure installation ___ provides superior hose and coupling integrity ___ allows re-installation of OE pressure sensors ___ protects vital areas of the hose ___ protects tube against rust and corrosion

Answers 1. a. pump b. power activating mechanism c. series of flexible hydraulic hoses 2. To assist the driver in turning the front wheels of the vehicle. 3. pump engine belt 4. a. integral b. rack and pinion c. hydro-boost d. linkage or booster e. remote reservoir 5. c. two or three 6. True 7. False 8. b. power steering system 9. b. linkage (booster) systems 10. a. dirt b. sludge 11. a. pressure lines b. return lines c. cylinder lines 12. True 13. True 14. c. 6,000 psi 15. OEM-type hose assembly 16. a. pumps b. rack and pinions c. gears 17. original equipment-quality components detailed instructions 18. economical 19. red stripe or red safety stripe 20. h c d g f a e b
Level 101 Review Quiz

b.

Why The Gates Power Steering Hose Line Is Superior To All Others
Gates has been building power steering hose for Original Equipment Manufacturers for 25 years thus developing a high degree of technical skill. All Gates OEM-type hose assemblies meet or exceed SAE specifications for quality and long service life. Tearn-Coated Tubes Protect against rust and corrosion

Original Style Fittings No adapters required Switch Sockets Allows re-installation of OE pressure sensors

DuPont Hypalon Hose Where specified by OEMs

Double Lock Beading with Barbed Tube End Provides superior hose/coupling integrity Restictor Absorbs vibration Reduces noise Silver Heat Guard Protects hose in high heat areas Split Conduit Hose (Convoluted) Protects vital areas

Braze-on/or Moveable Mounting Bracket For easy, secure installation

End Lock Tabs Prevent hose end from loosening

Safety Stripe
All Gates pressure and cylinder line hoses have a distinctive red stripe the mark of assurance that the hose will give long service life under extreme operating conditions.

Hose Tube
Hypalon tube construction withstands internal oil temperatures up to +300 F for extended periods without deteriorating.

Controlled expansion characteristics of hose assures proper resistance to fluid surges. Hose is built under rigidly controlled conditions to insure uniformity throughout and to afford equal holding properties for couplings and end fittings. Hose is engineered to act as a muffler to suppress pump noises thus assuring quiet operation.

Hose Cover
Hypalon (CSM) resists oil, heat and ozone conditions which cause ordinary hose to fail prematurely.

Unique Crimping Methods

Ensure uniform connections between hose and end fittings.

Reinforcement
Two plies of high-tensile-strength braided fabric help pressure and cylinder line hose to withstand pulsation pressures up to 1,500 psi, and bursting pressure up to 8,900 psi.

Safety and Comfort Oriented

Built-in shock absorbing features in pressure and cylinder line hose absorb fluid back pressure caused when car wheels hit rough obstacles.

A registered trademark of DuPont.

The Gates Rubber Company 900 South Broadway P.O. Box 5887 Denver, Colorado 80217-5887 www.gates.com
Printed in U.S.A.