ACE return line - abrasion leak

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Detroit Disco

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Czech Republic
Noticed some oil dropping on the driveway, left side of vehicle, near wheel. ACE fluid was a bit low.

Opened it up to discover that what I assume is the (relatively) low-pressure return line has an abrasion leak. See attached photo. Looking at the situation, I believe that the independent secured the line with a zip tie after swapping my steering gearbox a couple of years back. The line rubbed against the pressurized intake tube (turbo discharge to intercooler intake) and is now leaking - but not penetrated.

Looking at the ACE diagrams, it seems like a terrible job to remove and replace any of these ACE lines - and it seems a shame to scrap the line for a failure in a straight section of steel tubing.

Q. Does anyone know what kind of pressure the return line possesses?
Q. Any advice on a DIY solution - that may have worked in the past?

Initial thoughts:
- Drain the line sufficiently to de-grease, and apply JB Weld (common US two-part 'metal' in a tube)
- Perhaps find a clamping patch of the correct size
- Cut line and use compression fittings to splice?

I'll look on line for the correct replacement line - but again, even if the price is reasonable, the installation seems really difficult given the ratio of steel : rubber line.

Appreciate the input / wisdom.
 

Attachments

  • 2019-09-11 ACE Line.jpeg
    2019-09-11 ACE Line.jpeg
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Briefly, the failed line appears to be part RQB000300. 65 GBP for the Br!tpart from a normal UK supplier. I've not had great luck with Br!tparts - happy to hear thoughts. Price is less than expected - but I'd still need to fiddle the line into place and manage to make a leak-free union to the existing line about half-way back in the truck.

Fiddling with some two-part 'metal in a tube' is sounding tempting.
 
Had a very similar prob with the downline from the reservoir to the pump. Pinhole in the metal part. Cut it out and replaced it with a flexi back to the reservoir, connected with a jubilee clip never had a problem since.
Almost all of your solutions seem reasonable. I'd be tempted to put a drop of solder,braze or weld on the pinhole.
But I wouldn't bother with the clamping patch. Honestly, if you can find a straight connector (compression) to fit, I'd do that.
While you are there, take of the panels from the wheel arches to the engine bay and go around with cable ties and bits of slit garden hose, you'll find tons of stuff that needs protection from rubbing!
 
Update: In the end, I began with the simplest solution - assuming if it didn't hold, I'd be cutting the line anyway. It's held for a couple weeks - and should be good for a while. Here's what I did:
- Using a bit of self-fusing tape, I covered the pinhole to temporarily stop the pin-hole of oil from flowing. Oil + epoxy don't mix.
- Thoroughly cleaned the line using alcohol. Repeat.
- Applied 2-part epoxy (JB Weld) to cover the entire area of damage - being careful to fully encapsulate the self-fusing tape

Stanleysteamer is 100% correct about abrasion in this area - I removed the inspection / splash panel (fiddly to get out) to initially diagnose and there are several lines in the area that should be buffered. These include AC line, ACE line, steering line(s), etc. It's likely worth a quick peek in here at least once per year to clean and check. I lost the simplest line of them all (a low-pressure ACE line) - all others in this area are far more difficult to replace.
 
Good for you, if it doesn't hold you can always go the weld/solder route.
Glad the tip about possible abrasion proved fruitful. Mad that they build them like that with so many problems just waiting to happen.
 
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