Power Steering Hose - Return

Replace the power steering return hose on a 2005 Dodge Viper 8.3L V10, including draining the system, removing the old hose, installing a new hose with fresh O-rings, and refilling/bleeding the power steering system.

Warnings

Tools required

Parts

• Power steering return hose assembly × 1 — Use OEM specification
• Power steering line O-rings × 2 — Use OEM specification
• Hose clamps (if not included with hose) × 2 — Appropriate size for return hose

Fluids

• ATF+4 — 2 qt

Preparation

1. Park vehicle on level surface and engage parking brake.
2. Allow engine to cool completely if recently operated.
3. Raise front of vehicle and support securely on jack stands.
4. Place drain pan under power steering pump and reservoir area.
5. Turn steering wheel fully left and right several times to circulate fluid, then center the wheel.

Procedure

1. 1

   Drain power steering fluid from reservoir
   Remove the power steering fluid reservoir cap. Use a fluid transfer pump or turkey baster to remove as much fluid as possible from the reservoir. This will minimize spillage during hose removal. Dispose of used fluid properly.
2. 2

   Access power steering return hose
   Locate the power steering return hose, which carries fluid from the steering gear (via the fluid cooler on the Viper) back to the reservoir/pump inlet. On the 2005 Viper, the return hose connects to the bottom or side of the reservoir and runs to a fitting on the steering gear or cooler. Trace the entire hose path to identify connection points and any clips or brackets securing the hose to the frame or body.
3. 3

   Disconnect return hose at reservoir
   At the reservoir end, the return hose is typically secured with a spring clamp or worm-gear clamp. Use needle-nose pliers to compress and slide the spring clamp away from the connection point, or loosen the worm-gear clamp. Twist and pull the hose off the reservoir fitting. Allow remaining fluid to drain into the pan. Plug the reservoir nipple with a clean shop rag to prevent debris entry.
4. 4

   Disconnect return hose at pump or steering gear
   At the opposite end, locate where the return hose connects to the fluid cooler / steering gear return circuit. Verify against factory routing that you are working on the low-pressure return line and not the high-pressure feed line before disconnecting. If secured with a clamp, release it as in the previous step. If connected via a threaded fitting, use a flare nut wrench to loosen the fitting. The return line is typically low-pressure and may use a compression fitting or threaded connection. Carefully disconnect the hose and allow fluid to drain completely.
   Torque spec

   Power Steering Line Fittings30 Nm (22 lb-ft)
5. 5

   Remove hose routing clips and brackets
   Work along the length of the old return hose and release any routing clips, brackets, or cable ties securing it to the frame, crossmember, or engine bay components. Note the routing path carefully for proper installation of the new hose. Take a photo if helpful for reference.
6. 6

   Remove old power steering return hose
   Once both ends are disconnected and all securing clips are released, remove the old return hose from the vehicle. Inspect the old hose for signs of wear, cracking, swelling, or contamination. Check the condition of the reservoir fitting and pump/gear fitting for damage or corrosion.
7. 7

   Prepare new return hose
   Inspect the new power steering return hose to ensure it matches the original in length and fitting configuration. If the hose uses O-ring sealed fittings, install new O-rings onto the fittings. Lightly lubricate O-rings with clean ATF+4 to ease installation and prevent tearing. If using clamp-type connections, ensure new clamps are available.
8. 8

   Route new return hose
   Route the new return hose along the same path as the original, ensuring it does not contact hot surfaces (exhaust manifolds, headers), sharp edges, or moving components. The hose should follow the factory routing with gentle bends and no kinks. Temporarily secure the hose path before making final connections.
9. 9

   Connect return hose at pump or steering gear
   Connect the fitting end of the return hose to the power steering pump, steering gear, or cooler. If using a threaded fitting with O-rings, hand-tighten first to ensure proper thread engagement and O-ring seating, then torque to specification using a flare nut wrench. If using a barbed connection, slide the hose fully onto the nipple until it bottoms out, then install and tighten the clamp securely.
   Torque spec

   Power Steering Line Fittings30 Nm (22 lb-ft)
10. 10

    Connect return hose at reservoir
    Push the reservoir end of the return hose firmly onto the reservoir nipple until fully seated. Install the spring clamp or worm-gear clamp over the connection point and position it approximately 1/4 inch from the end of the hose. Ensure the clamp is tight and the hose connection is secure.
11. 11

    Secure hose with routing clips
    Install all routing clips, brackets, and cable ties to secure the return hose in its proper position. Ensure the hose does not contact moving parts, exhaust components, or sharp edges. The hose should be supported at regular intervals and not hang loosely.
12. 12

    Refill power steering system
    Fill the power steering reservoir with fresh ATF+4 fluid to the cold fill line or maximum mark. Add fresh ATF+4 to the cold fill line, verifying total system capacity against the OEM service specification, and top off as needed after bleeding to replace fluid lost during the procedure. Do not overfill.
13. 13

    Bleed power steering system
    With the engine off, turn the steering wheel slowly from lock to lock 10-15 times to purge air from the system. Check the fluid level frequently and add ATF+4 as needed to maintain proper level. Once no more bubbles appear in the reservoir and the fluid level stabilizes, start the engine. With the engine at idle, turn the steering wheel slowly from lock to lock 5-10 times. Check for leaks at all connection points. Add fluid to bring the level to the hot fill mark. Continue checking and adding fluid until the level remains stable and no air bubbles are present.

Reassembly

1. Lower vehicle from jack stands.
2. Start engine and verify no leaks at return hose connections.
3. Test drive vehicle and verify normal power steering operation with no noise or cavitation.
4. Recheck fluid level after test drive and top off if necessary to hot fill mark.

Verification

• Visually inspect all connection points for leaks with engine running.
• Turn steering wheel from lock to lock while stationary and verify smooth operation with no whining or groaning noises indicating air in the system.
• Check power steering fluid level in reservoir and confirm it is at the appropriate hot fill mark after system reaches operating temperature.
• Verify return hose is properly secured and does not contact any hot or moving components.

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