I was wondering if anyone have tried making custom AN lines/Fittings for all the power-steering system. i wanted to replace my 33 year old lines thats leaking.

 

you probably could, but you need to make sure that the AN lines can handle the pressure, and then its probably not going to be any cheaper.

you might take your old lines to a hydraulic shop and see if they can replace the hoses

 

Rockauto sells both high and low pressure PS hoses for an S4. These two hoses will only set you back about $35.

 

you guys know what the size of fitting that goes from the cooler to the rack? thats the one its leaking.
the one marked in yellow..
i was wondering to bypass the line without a cooler.....

 

Return line circled yellow is M16x1.5, the middle high pressure line banjo is m12x1.25 (oddly M16x1.5 for a jdm rack), and the bypass line banjo is M12x1.25..If replacement lines are that cheap then it's easiest to buy replacement lines from someone like rockauto..If you were doing a conversion like electric power steering then Russel has a m16x1.5 to 6AN fitting you can make an AN line with. The middle port is a problem ,as there are M12x1.25 to 6AN fitting( although harder to find)....all of them aren't deep enough and result in just 2 full turns of the fitting to secure...banjo bolt has 5 full turns...I guess it works as I see people use them but I wouldn't be comfortable doing it..the other solution is to go to a hydraulic shop and buy a 6AN weld bung and cut the metric end off the banjo line and either silver solder(what the hydraulic shops do) or have someone silicon bronze tig the bung on.

 

does the banjo bolt has any copper washers? i dont think i saw one when i removed....

 

no it has o rings, which is odd