I benched the steering rack for refurb and found one of the metal pipes almost worn right through - and of course it is no longer available and of course this is Jaguar / ZF so anyone care to guess what is needed to make up pipes for these things - the OD of the pipe is a none standard (at least in brake terms 6mm) and although I have a professional grade tool with dies I do not have a die for 6mm OD - 1/4 SAE is close but not close enough.

Tempted to throw in the towel and just get a reconditioned rack - but some of those I've seen are what I would call 'rattle can' refurbs - or I need to track down the dies to make new line - what pressure rating does this line have and can you even get hold of it in non commercial batches.

Has anyone here ever remade pipe C45306 (or AEU2519) from the drawing below ? .... what did you use ?

 

i might actually have a brand new old stock one of these, i will check tomorrow

i also have a full NOS steering rack for sale,

BB

 

I am all ears and waiting with baited breath, let me know on either item, you can PM prices etc if you do have.

 

Ben
I may have misunderstood your post in my reply below. Are you after the pipe you bracketed in yellow?
My reply below is about the reservoir to rack pipes.

The pipes are available.
Second, I bought the pipes several metres of each from Wrights Auto Supplies, the rest of the bits from elsewhere: the flare fixing nuts and a top notch flaring thingy, AND a really nice pipe bender for under 200 euroquids, which is not much more than the pipes. For the return hose jubilee clips are fine to fix the flexibles. For the pressure hose, an aircon guy will swage them, or make a flare in the pipe and double clip it.
The pipe sizes are:
The steering rack power steering connections are 1/2 inch UNF (1/2 - 20) flare nuts for 5/16ths tube and 5/8 UNF (5/8 - 18) flare nuts for 3/8 inch tube. Different sizes for the input and return. Available on Amazon USA in brass which is better than steel. You need a double SAE flare on the pipes.
I happen to know all this as I recently made up a set which, including all the tools and materials was still cheaper than buying a set, and much better quality! Also you can make better pipe runs. These sizes of tubes and nuts are more usually found in home airconditioning systems.
The ZF rack and the earlier Adwest are the same thread sizes.

 

Yes the pipes in yellow.

Not according to SNG Barratt, DG Manners and Simply Performance - and my tubes are very definitely 6mm OD but I'll go measure again in case old farts disease is in play,

 

Measuring complete - they are 6mm OD give or take .02. To compound the misery I measured the fitting which has a thread OD of 10.4mm - which on my books says it is 1/8 NPT.

I do have a commercial turrent former for hydraulic fittings but nothing in it works with these dimensions. I'll do some hunting and see what I can find out about the pipes and the fittings.

 

Not trying to sound like good mechanic here, at all, but:

When I first got my car and started it, turned the wheel, I noticed this fine white smoke coming from under the hood. Yup, that exact line. I was scared and had NEVER dealt with anything line this before. On closer look both lines looked bad... One had a rust pin hole and a sweet stream of fluid shot directly onto the cat (which were later deleted)...

If I remember, and if it isnt that STRANGE pressure fit line that runs the horizontal, I removed the rack, then the line, with fittings still on and tried as best I could to match, bend a new line, then cut the old, flared the new, and reused the fittings.

No no no fun for the inexperienced first timer - that was, and in many cases still does, describe me, lol. See my latest thread to confirm. hahaha

Anyways. Still have the same line,,, but recently a LEAKING rack, smh... Does it even end!?

 

Does it ever end --- seemingly not and it does get a little 'tiring' I have to say - I have yet to have a job on this car that didn't lead to at least one more.

This was supposed to be a 'simple' seal replacement, I cleaned the rack off prior to disassembly as I do with anything and then I saw it, and once seen it cannot be unseen.

For similar reasons to yours I have just committed to a full rebuild by a company here called K B Steering that specialise in these things and have pipes specially made - they didn't want to disclose the details and I get that other than the lead time on them is measured in months apparently. I simply don't want to be pulling this rack again any time soon and I want it fitted to the subframe before I lift it into position along with all sundry heatshields etc

 

these are what i was referring to , havnt touched em since restoring and running my XJS that is now sold , kept as essential spares that never got used ,

 

Dare I ask how many body parts I would need to trade ?