I couldn't find these instructions elsewhere, so I hope I'm not duplication an existing thread:

I've recently replaced my PS pump and fan, and noticed a small leak from the suction line, so I went ahead and replaced that, too. I refilled the PS reservoir to bleed the system, and started the car, only to find a huge puddle of foamy Pentosin forming (immediately!) on the garage floor. Upon further inspection, it appears that my return hose is dumping fluid. D'oh!

I can see the bolt that needs to be removed from the steering gear, but I don't have a tool that seems to fit appropriately into that space. Any suggestions? Also, does anyone know the size of that bolt head? It's bigger than my socket set includes, which I think goes up to 18mm.

 

The way that you get the top one off is to remove the bottom one first. the size of the lower banjo bolt is 19mm. the top is 21 or 22mm. I recommend that you use a chrome socket and a swivel. Also make sure you replace the crush washers on the lines.
fred

 

Are you sure it's the return hose? I just R&R'd my pump this weekend and I didn't have to go anywhere near the return hose. The pressure hose from the pump has an end that can be difficult to fit fully into the pump. It's held in by a bolt but you have to get the fitting properly lined up or it won't seat all the way.

Eric

 

FYI: I did NOT have to remove the lower bolt in order to remove the top one. And the top bolt is definitely 22mm. I know because I had to replace my return hose last weekend. The largest I had on-hand was 19mm. Ran to Home Depot, grabbed a 21mm (the largest metric they had) and it didn't fit. Then ran to AutoZone and grabbed a 22mm & 23mm. It's the 22mm alright. But even with a swivel and 10" extension bar attached to my socket wrench, access that top bolt was a royal pain!

Took me 5 hours to replace the hose (including travel time to get the tools).

I posted the details and pics here.