Power Steering Hose - Return

Remove and replace the power steering return hose on a 1992 Dodge Viper, including draining the system and refilling with fresh fluid.

Warnings

Tools required

Parts

• Power steering return hose × 1 — Use OEM specification
• Hose clamps (if not reusable) × 2 — Match OEM size

Fluids

• Mopar power steering fluid or ATF+3 — 1.5 qt

Preparation

1. Park vehicle on level ground and apply parking brake.
2. Place wheel chocks behind rear wheels.
3. Turn steering wheel fully left, then fully right, then center to identify full range of hose movement.
4. Remove power steering reservoir cap to vent system.
5. Use turkey baster or fluid pump to remove as much fluid as possible from the reservoir to minimize spillage.

Procedure

1. 1

   Raise and support vehicle
   Raise the front of the vehicle and support securely on jack stands at the front jacking points. The return hose routing is best accessed from below on the Viper platform.
2. 2

   Locate return hose routing
   Identify the power steering return hose. It runs from the steering gear return port back up to the power steering reservoir/pump on the driver side of the engine. The return line is the lower-pressure hose, typically smaller diameter than the high-pressure line and secured with worm-gear style hose clamps rather than threaded fittings at the pump and reservoir ends.
3. 3

   Position drain pan at reservoir connection
   Place drain pan beneath the power steering reservoir connection point. This is located on the passenger side of the engine bay.
4. 4

   Disconnect return hose at reservoir
   Using hose clamp pliers or flat-blade screwdriver, loosen the hose clamp securing the return hose to the reservoir nipple. Slide the clamp back along the hose. Twist the hose gently while pulling to break the seal and remove it from the reservoir. Allow fluid to drain into the pan. Inspect the clamp for damage or excessive corrosion; replace if necessary.
5. 5

   Disconnect return hose at steering gear
   Move the drain pan beneath the steering gear connection point (located at the steering rack assembly, center-front of vehicle behind the crossmember). Loosen the hose clamp at the steering gear return port using the same method. Twist and pull the hose free. Additional fluid will drain from both the hose and the gear. Note the orientation and routing of the hose for installation.
6. 6

   Disconnect return hose at power steering pump
   Access the power steering pump on the driver side of the engine block. The pump is driven by the serpentine belt. Position the drain pan beneath the pump return connection. Loosen and remove the hose clamp, then twist and pull the return hose from the pump fitting. Residual fluid will drain from the pump.
7. 7

   Remove return hose from vehicle
   Carefully extract the return hose from the engine bay and undercarriage, noting any clips or routing guides it passes through. The Viper's tight engine bay requires careful threading of the hose past the exhaust headers and frame rails. Take photos or make notes of the exact routing path, including any heat shields or brackets the hose passes through.
8. 8

   Inspect fittings and connections
   Examine the reservoir nipple, steering gear return port, and pump return fitting for cracks, corrosion, or damage. Clean any debris or old fluid residue from the connection points using shop rags. Verify that all fittings are tight and not damaged.
9. 9

   Route new return hose
   Thread the new return hose through the engine bay following the exact path documented during removal. Ensure the hose does not contact exhaust components, sharp edges, or moving parts (serpentine belt, pulleys). The hose must have sufficient slack to allow full steering range without stretching or kinking. Do not connect ends yet; simply position the hose along its route.
10. 10

    Connect return hose to power steering pump
    Push the return hose firmly onto the pump return fitting until it bottoms out against the fitting shoulder. Position a new or reusable hose clamp approximately 1/2 inch from the hose end, over the fitting barb area. Tighten the clamp securely, ensuring the hose cannot pull free but avoiding over-tightening that could cut the hose.
11. 11

    Connect return hose to steering gear
    Attach the return hose to the steering gear return port using the same technique: push fully onto the fitting, position the clamp over the barb area, and tighten securely. Verify the hose is not twisted or kinked between the pump and gear connections.
12. 12

    Connect return hose to reservoir
    Push the return hose onto the reservoir nipple until it seats completely. Install and tighten the hose clamp. Double-check that all three connections are secure and clamps are properly positioned.
13. 13

    Lower vehicle
    Remove jack stands and lower the vehicle to the ground. Perform a visual inspection from below one final time to ensure no interference with suspension or exhaust components through the steering range.
14. 14

    Fill power steering system
    Fill the power steering reservoir with Mopar power steering fluid or a compatible ATF (per owner's manual, ATF+ / Dexron for this era) to the cold fill line (approximately 1.5 quarts total system capacity). Do not overfill. Leave the cap off for the bleeding process.
15. 15

    Bleed power steering system
    With the engine off, turn the steering wheel slowly from full left to full right 10-15 times. Check fluid level frequently and add fluid as needed; the level will drop as air is purged and fluid fills the system. Once the level stabilizes, start the engine and let idle. Turn the steering wheel slowly lock-to-lock 3-4 times while the engine runs. Check for leaks at all hose connections. Add fluid to bring level to the hot fill line. Install reservoir cap.

Reassembly

1. Reassembly is integrated into the installation steps above.
2. Ensure all hose clamps are positioned over the fitting barb areas and tightened securely.
3. Verify the return hose does not contact exhaust components or moving parts through full steering range.
4. After bleeding, the fluid level should be at the hot fill line with the engine at operating temperature.

Verification

• Start the engine and verify no leaks at the reservoir, pump, or steering gear connections.
• Turn the steering wheel through full range while stationary; listen for whining or groaning that would indicate air in the system or low fluid.
• Check power steering reservoir fluid level; it should be at the hot fill line after the system reaches operating temperature.
• Test drive the vehicle at low speed in a parking lot, turning the wheel through full range in both directions. Steering should be smooth and quiet with no fluid leaks visible underneath.

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