Good idea, Team Adidas.

Also, if neither the supply line nor return line is leaking, you may just want to check for obstructions in the lines at the banjo bolts where they connect to the steering gear. If something happened to get in the supply line, say at the reservoir, it could get lodged at the banjo bolt and would cause an obstruction. In my case--and at the risk of highlighting a stupid mistake I once made--it was a tiny, protective rubber plug on the supply port that the pump rebuilder inserted to look like it was part of the pump. The plug worked its way under pressure from the pump all the way through the supply line to the gear box where the line bolts on. I found it melted into the hole in the banjo bolt there.

When I pulled the front of the pump off to investigate, it was apparent that the system was overheating due to no flow, because the plastic retaining seal on the cam cover had actually melted. The pump also made a groaning noise while operating. It took me about 20 hours of troubleshooting to finally figure that one out.


I changed my supply line last week because it was leaking. It was fairly easy to get to because it is the closest to the bottom at the steering gear. The return line banjo bolt is up a few inches higher and you will need either an 18 mm or 19 mm (I can't remember) open-end wrench to get it loose (an offset open-end wrench would have probably been even better). I couldn't fit a socket on it.

The supply line was a no-brainer to replace because it wasn't mounted to anything or routed through an inaccessible area. The return line runs all the way to the back of the reservoir, but I suspect the rubber portion is accessible without removing the reservoir itself. Maybe Team Adidas can confirm this.

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1993 400E, 256,000 miles (totaled)
1994 E420, 200,000+ miles
1995 E420, 201,000 miles