Power Steering Hose - High Pressure

This procedure covers the removal and replacement of the high-pressure power steering hose on a 1966 Chevrolet Corvette with 327ci V8 engine, including fluid drainage and system refilling.

Warnings

Tools required

Parts

• High pressure power steering hose × 1 — Use OEM specification or exact-fit aftermarket
• Power steering hose O-rings (if applicable) × 2 — Check hose end fittings for replaceable O-rings

Fluids

• GM Power Steering Fluid — 1 qt

Preparation

1. Park vehicle on level ground and apply parking brake
2. Place wheel chocks behind rear wheels
3. Allow engine to cool completely if recently operated
4. Raise front of vehicle and support securely on jack stands
5. Turn steering wheel fully left, then fully right (engine off) to relieve system pressure
6. Place drain pan under power steering pump and steering box areas

Procedure

1. 1

   Remove fluid from power steering reservoir
   Using a turkey baster or fluid pump, remove as much power steering fluid as possible from the reservoir mounted on the power steering pump. This minimizes spillage during hose removal. Dispose of old fluid properly.
2. 2

   Locate high-pressure hose connections
   Identify the high-pressure hose routing. On this vehicle the pump feeds a linkage-mounted control valve and power cylinder system. The high-pressure hose connects from the outlet port on the power steering pump (driver's side of engine) and runs along the frame to the control valve. Confirm the exact fitting and routing against the actual vehicle, as the hose ends and routing depend on the control-valve/power-cylinder configuration. The hose has threaded fittings at both ends.
3. 3

   Disconnect hose at power steering pump
   Using a flare nut wrench to prevent rounding, loosen and remove the threaded fitting connecting the high-pressure hose to the power steering pump outlet port. Position drain pan to catch fluid. Once loose, unthread by hand and allow fluid to drain. Cap or plug the pump outlet port to prevent contamination.
4. 4

   Trace and release hose routing clips
   Follow the hose from pump to steering box, identifying any mounting clips or brackets securing the hose to the frame or engine. Identify and note the number and location of any clips or brackets securing the hose along its routing (verify against the actual vehicle). Use a screwdriver or appropriate tool to release these clips without damaging them for reuse.
5. 5

   Disconnect hose at steering box
   Locate the threaded fitting where the high-pressure hose connects to the steering box inlet port on the frame rail. Position drain pan beneath. Using a flare nut wrench, loosen and remove the fitting. Unthread by hand once loose and allow remaining fluid to drain. Cap or plug the steering box inlet port.
6. 6

   Remove old high-pressure hose
   Carefully maneuver the old hose out of the engine compartment, noting its exact routing path, bends, and clearance points. Pay attention to how it clears the exhaust manifold, engine mounts, and frame components. Take photos if helpful for routing the new hose.
7. 7

   Inspect fittings and ports
   Clean the threaded fittings on both the power steering pump outlet and steering box inlet using a wire brush. Inspect threads for damage or debris. Check if the old hose has replaceable O-rings at the fittings; if so, prepare new O-rings for installation on the new hose.
8. 8

   Prepare new high-pressure hose
   Compare the new hose to the old hose to verify correct length and fitting configuration. If the fittings have replaceable O-rings, install new O-rings now, lubricating lightly with clean power steering fluid. Ensure no protective caps or plugs remain in the hose ends.
9. 9

   Route new hose
   Route the new high-pressure hose following the exact path of the original, ensuring adequate clearance from exhaust manifolds, sharp edges, and moving components. The hose should follow the frame rail without kinks or tight bends. Loosely install routing clips as you go.
10. 10

    Connect hose to steering box
    Thread the fitting at the steering box end by hand to ensure proper engagement without cross-threading. Once hand-tight, use a flare nut wrench to snug the fitting. Tighten firmly but do not over-torque as this can damage the fitting or port threads. The fitting should be tight enough to prevent leaks under pressure but not excessive.
11. 11

    Connect hose to power steering pump
    Thread the fitting at the pump outlet port by hand until seated, ensuring straight engagement. Use a flare nut wrench to tighten firmly. Apply the same principle as the steering box connection: tight enough to seal under pressure without damaging threads.
12. 12

    Secure hose routing clips
    Verify the hose routing maintains proper clearance throughout its length, then fully secure all original mounting clips along the routing. Ensure the hose cannot contact the exhaust, frame edges, or suspension components through the full range of steering travel.
13. 13

    Fill power steering reservoir
    Remove the power steering reservoir cap. Fill the reservoir with ATF (Type A or Dexron-compatible) to the FULL COLD mark. Do not overfill. Reinstall the cap loosely for the next step.
14. 14

    Bleed air from system (initial)
    With the engine still off, turn the steering wheel slowly from lock to lock 10 times. Check the fluid level after every few cycles and add fluid as needed to maintain the FULL COLD level. This purges initial air from the system.
15. 15

    Start engine and complete bleeding
    Start the engine and allow it to idle. Turn the steering wheel slowly from lock to lock 5 times while the engine runs. Check for leaks at both hose connections. Shut off the engine and recheck the fluid level, topping off to the FULL HOT mark if engine is warm or FULL COLD if still cool. Tighten reservoir cap.

Reassembly

1. Lower vehicle from jack stands
2. Remove wheel chocks
3. Clean any spilled power steering fluid from components and frame
4. Dispose of old power steering fluid and hose according to local regulations

Verification

• With engine running, turn steering wheel fully left and right while checking for leaks at pump and steering box connections
• Verify no unusual noises (whining or groaning) from power steering pump during operation
• Check power steering fluid level after test drive and top off if necessary
• Verify smooth power steering assist throughout full range of steering travel
• Inspect hose routing for adequate clearance from all moving and hot components
• Recheck all connections and fluid level after 50-100 miles of driving

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