I could see that access was tricky since they decided to surround the sphere with pipes, an engine, a radiator and a bit of subframe that joins to the cross member. But I just managed to get the truck spec. oil filter wrench around it slightly insecurely. Indeed if it hadn't been for the fact that it was not tight I'd still be there...
However once loosened there was no route to remove the old sphere due to a coiled bit of pipe in the way. Fine, I'll do a bit of subtle bending to create space (balls to removing the fugger)
It was after bending it back that this happened
shit. this was supposed to be one of my famous 'just before dinner' jobs that turned out to be a right kok. The pipe in question is the one that goes from the FDV valve to the pinion valve.
Thinking I had crippled the car and I'd need to leave it in the garage until I sourced a replacement pipe I went into a bad mood and had some tea and a rummage through my spare odds and ends. I found a spare pipe and went to check the length - it looked like it might even fit until I realised it was one of the 9mm union pipes - darn it. Then I checked back and realised that this WAS the right diameter and union nut! great!
spare pipe here.
Of course, the pipe was a total 'mare to remove, especially at the steering pinion end. It is completely inaccessable from all angles and you can get a 9mm spanner to it from behind the sub frame but only manage turns of about 10 deg a time... it was going to be a long task. The FDV connection was easier but still a swine to reach as it's higher up and again has no room to swing a spanner. Removing the new sphere again helped a bit (I would've done the ball bearing reseat job if I actually had a brass punch) then after removing the 2 pipe clips the thing fell apart at the leak - that's how marginal the pipe must have been!
You can see that the corrosion on the pipe has happened where the anti vibration sponge rubber thing sits. Here you can just about see how thin the pipe had become
I believe the pressure supply to the pinion valve is less than the line pressure of the rest of the circuit and that is why it didn't blow out previously.
Anyway after a huge amount of effort to get the 'new' pipe back in - it was so much harder due to the fact that I was continually reforming it to fit the original. Couldn't use orig. as a template as it was bent beyond recognition.
All fixed now and the accumulator has made a massive difference to the brake pedal feel, the suspension moves without putting the warning light on and the HP pump is a bit quieter.
Moral of the story: when people tell you that all your old 'junk' of spares etc is , well junk, ignore them. Those parts WILL come in useful one day!
I don't know what the pipe fitted originally (possibly the pipe on a GSA that goes from the PRV to the security valve) but it was worth keeping in the dungeon with all the other crap.
