power steering lines (holes rubbed through)

[crash]

I had the misfortune of discovering that one of my power steering lines had a hole rubbed through - it was rubbing on the metal tube from the turbo to intercooler, then discoverd the line from the resevoir to the pump almost had a hole in it from rubbing on the engine.

I spent over 2hours getting the 2 long lines that run across the front of the vehicle out. In the rave they say they run along the cooler pipe and look fairly straight forward to get out - undoing about 5 clips. On my 02 Disco TD5 they run under the intercooler and AC rad, and there are two clips with two bolts that undo the clip that are almost impossible to get undone without taking the radiator out - I was eventually able to undo them by twisting the lines around to where I could get a spanner onto them. I am worried about how I am going to fasten these clips once the new lines go in. Only other possible way may be with a long extension bars and come down from between the intercooler and rad but the bolts are hard to see from looking from the top.
Had to manually alter the shape of the lines abit to eventually get them out. Had to undo the clips to seperate the two lines as I was not able to pull them out together - had to seperate them and pull them out individually.

Does anyone know what the fluid capacity for the Powersteering resevoir / pump and steering box are - can not locate it in Rave?

Any advice on putting these lines back in appreciated.

[winaje]

I had that happen about 7 years ago. I cut the flange off just above where it had rubbed through, then cut off the minimum amount of rubber pipe possible just above the flange. Pushed the rubber pipe over the metal, then used a hose clamp directly on top of the wear through point. Been that way for 7 years with no leaks.

I'm pretty sure that the reservoir can be unclipped from it's holder which should make it a lot easier to refit the pipes, can't remember how I did it though, sorry.

[crash]

The resevoir just slides out of its bracket.
Took all the lines into the local hose joint getting differnt connections put on so can easily replace the rubber sections in the future.
Feeding the lines through under the radiator is going to be fun and doing up two clips are the stumbling blocks.

[Hay Ewe]

Just over two years ago had same problem
for the volume what we did was:-

fill reservoir
start engine
top off reservoir
steering full to the left, then full to the right, back to left, back to right
continuously filling the reservoir up to the line

If you just fill the reservoir to the line, when the pump bleeds out the air, there wont be enough fluid.
we did this stationary and monitored if for a while

[crash]

All back together and working fine with no leaks.
Took about 1 1/2 litres of fluid all up.
I took the lines to a hydraulic place and had all the rubber hoses changed over to screw on fittings so in future I will just have to replace a small section of rubber hose.
The brackets under the radiator still causing drama's, at the moment everthing is cable tied tight. I have a couple of ideas of modifying the bracket to make it easier for future.
I have alos gone a bit crazy with heavy duty hose around all of the new hoses on any potential rub points.