My return line is leaking right at the fitting in the rack. (Looks like my truck alternator has been pushing against it and it finally failed). Rather than buying the stock return line, I want to take advantage of the opportunity to get rid of the factory cooler and add a frame-mounted one. I'm going to replace the fitting with a 90 degree turn to clear the alternator and buy a generic line to go from the rack to the cooler and then the cooler to the reservoir... What fitting do I need to replace the one in the rack though? :/

 

The return line is low pressure and the only thing sealing the line to the rack is a simple o-ring. A new o-ring should be the only thing needed to fix the leak of that line at the rack.

If you want to make up a new line, just use a dremel tool to cut the permanent press clamp that holds the rubber hose to the metal part of the original line to the metal part. (The rubber hose will come off.) You can then polish up the metal with some steel wool and brake cleaner - it should look good as new. With a new O-ring and a simple hose clamp, you should be back in business and able to add whatever rubber hose you want for your bypass.

 

Thanks Wssix99. Only way I may be able to make that work is cutting the hard line just as it comes off the rack and clamping the bypass hose right there.. The alternator is pushing on the hard line and (I'm assuming) caused this leak. I'm hopeful on your suggestion for just a new o-ring fixing it, but I need to address the hard line being pushed aside as well.

 

Do you have an aftermarket alternator, custom setup or is there a possibility your return hose isn't original? There shouldn't be any interference to begin with.

 

Yeah, oversized alternator... :/

 

I would not cut the tube because there should be a flare to help the hose clamp cinch down on the pipe. You should be able to bend it, though. (-> With an appropriate tube bending device. This may be a great excuse to get a new tool...)

Pictures would be great here. Inquiring minds want to see and a picture + solution will likely help several more people down the road.

 

Going from the stock Alt to a AD244....you have to bend the return line to avoid interference.....return lines including the hard line are available from aftermarket.....of course NLA from GM....if you wish to replace just the rubber line....you can just get hydraulic hose from Derale

 

Thanks for the replies all. I don't have pics of the solution as of yet, as the parts haven't all arrived. I ordered a PQY power steering return hose kit (with a new fitting & 90 degree bent hard line) and a Derale frame rail cooler. Since I'm touching the return, I'm going to go ahead and at least route around the crappy stock cooler. I'll worry about replacing the coolant hose at a later date.
Here's a pic of the leak and the hard line up against the alternator. The alternator has been in there for 5 years, so I guess it has just been a ticking time bomb since then.

 

Parts are here...hopefully I'll get some time this weekend to get it flushed & put back together.