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joewhite2417
Trainee


Joined: 09 Jun 2015
Posts: 53



PostPosted: Sun Apr 15, 2018 1:55 pm    Post subject: Steering rack woes Reply with quote

Hi folks,

A couple of weeks ago I noticed a howling from the power steering pump caused by a lack of power steering fluid.

I've since pulled of the under-body plastics and found where the fluid has gone!

On first glance it looked like the fluid was pouring out of the back of the rack gator which would signify that the seals in the rack had gone.

Closer inspection has revealed that the thin pipes on the rack have corroded through, and the fluid is leaking from one of these pipes.

My question is... Can these pipes be replaced with the rack in-situ? Has anyone carried out this task?

I'm having considerable difficulty disconnecting the feed pipes from the rack. The corrosion seems to have welded them in place. Does anyone have any tips on getting these free?

Thanks guys!

Joe
 
  
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Robertb
Long Beach


Joined: 01 Sep 2003
Posts: 6723
Location: South Oxfordshire

2002 Porsche 996 Carrera 4S

PostPosted: Sun Apr 15, 2018 2:24 pm    Post subject: Reply with quote

Hopefully Wasz will be along soon- he knows about steering pipes and has a source for replacement rather than buying the whole rack like Porsche insist.
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wasz
Magny-Cours


Joined: 28 Dec 2012
Posts: 2643


1999 Porsche 996 Carrera 2

PostPosted: Sun Apr 15, 2018 7:56 pm    Post subject: Reply with quote

Hi yes I had a local mechanic do these on my car (I had no time).

You can buy just the hard pipes for £40 here: https://tinyurl.com/y9vl9q3s or any local hydraulic hose place (pirtek?) could make them up.

He had to drop the subframe a bit to gain access.

You should change the brake line that runs across there too while you are in there as it will be crusty.


In dropping the subframe, he dropped the rack off the end of the steering column. My car is an MY99 and these had a plastic coating on the column splines. Over the years this had degraded and came away from the splines when it was removed.... so also needed replacing. However an MY99 (unlike later cars) have a one piece steering column Sad so the whole lot had to be swapped. I managed to get a good used one for £50 though. Later cars the lower UJ and splined bit is a separate replaceable piece.

Just be aware that the same might happen to you if its an early car.
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My special order Vesuvious Charcoal 996 | Clutch, Fly RMS IMS AOS Job |
Steering Rack Hard Lines | Air Con Compressor / System
 
  
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joewhite2417
Trainee


Joined: 09 Jun 2015
Posts: 53



PostPosted: Sun Apr 15, 2018 8:42 pm    Post subject: Reply with quote

Hi Wasz

Thanks for the info. I bought a second hand rack on eBay this morning (before I had properly diagnosed the leak) that looks to have decent pipes on it.

Mine's a MY2002, so shouldn't have the same issue. The big struggle will be getting the pressure lines off if I need to pull the rack out, so I've ordered a slide hammer and gallons of Lusol!

Cheers again

Joe
 
  
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wasz
Magny-Cours


Joined: 28 Dec 2012
Posts: 2643


1999 Porsche 996 Carrera 2

PostPosted: Sun Apr 15, 2018 9:22 pm    Post subject: Reply with quote

Fair enough. Might be easier and cheaper to fit new lines to yours though and return the other rack (remember if you paid by PayPal then PayPal will refund your return delivery).

Or you could fit new lines to your old rack and sell it on.
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My special order Vesuvious Charcoal 996 | Clutch, Fly RMS IMS AOS Job |
Steering Rack Hard Lines | Air Con Compressor / System
 
  
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Stoo.c
Monza


Joined: 07 Apr 2014
Posts: 193
Location: Hertfordshire


PostPosted: Mon Apr 16, 2018 9:24 am    Post subject: Reply with quote

I cant believe how cheap those pipes are and free UK delivery. I've just bought a pair based on the fact that I'm going to need them at some point - may as well do it as a preventative measure.
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93 Skyline R33 GTS-t
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Paynewright
Trainee


Joined: 17 Apr 2018
Posts: 60
Location: Nr Lutterworth Leics


PostPosted: Tue Apr 17, 2018 1:21 pm    Post subject: Reply with quote

My rack pipes look particularly scabby. As I'm having the suspension apart shortly it makes sense to change them. I only live 1/2 hour away from the Power Steering Store in Balsall Common so have arranged to pop over and collect them.

I'll be checking out the L to R brake pipe too!


Ian
 
  
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wasz
Magny-Cours


Joined: 28 Dec 2012
Posts: 2643


1999 Porsche 996 Carrera 2

PostPosted: Tue Apr 17, 2018 3:19 pm    Post subject: Reply with quote

Yeah worth swapping them if you are getting a geo done and they are crusty.

You don't really want to do it twice or be stranded.

Put jubilee clips over the crimp ferrules on the flexible lines while you are there.
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Steering Rack Hard Lines | Air Con Compressor / System
 
  
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Stoo.c
Monza


Joined: 07 Apr 2014
Posts: 193
Location: Hertfordshire


PostPosted: Tue Apr 17, 2018 4:14 pm    Post subject: Reply with quote

Stoo.c wrote:
I cant believe how cheap those pipes are and free UK delivery. I've just bought a pair based on the fact that I'm going to need them at some point - may as well do it as a preventative measure.


..................and they arrived today - can't fault that.
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02 996 C4S
93 Skyline R33 GTS-t
91 CRX vtec turbo
01 986 Boxster S
 
  
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joewhite2417
Trainee


Joined: 09 Jun 2015
Posts: 53



PostPosted: Wed Apr 18, 2018 9:47 am    Post subject: Reply with quote

Has anyone dropped their front sub-frame? I'm planning on tackling it this weekend.

If anyone has a DIY on this, I'd be glad to hear about it. I found a couple of pages on 6speedonline and Rennlist that may come in handy, but if anyone has any hints or tips, I'd love to hear them.

Cheers

Joe
 
  
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joewhite2417
Trainee


Joined: 09 Jun 2015
Posts: 53



PostPosted: Fri Apr 20, 2018 7:28 pm    Post subject: Reply with quote

Here's a quick update. I've dropped the anti-roll bar and it looks like I will be able to access the flare nuts on the two hard pipes.so with a bit of luck, I should be able the replacement of all of the necessary bits and pieces without dropping the subframe. Mike's is a C4 and the front transfer box is attached to the subframe, so I'm not sure if I'd have to dismantle this as well.
 
  
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Paynewright
Trainee


Joined: 17 Apr 2018
Posts: 60
Location: Nr Lutterworth Leics


PostPosted: Fri Apr 20, 2018 8:43 pm    Post subject: Reply with quote

Thanks for the update - I’m collecting the new pipes next week and changing all the shocks after the bank holiday. Mines a C2 so hopefully less in the way!

Regards

Ian
 
  
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joewhite2417
Trainee


Joined: 09 Jun 2015
Posts: 53



PostPosted: Sun Apr 22, 2018 4:12 pm    Post subject: Reply with quote

Another update and a cry for help!

I dropped the sub-frame slightly as access to the pipes was very limited. Long story short... It didn't help! I only managed to create a small bit of space and I couldn't get a spanner onto the hard pipe flare nuts at the end of the rack.

I decided the only way forward was to pull the rack out. I managed to get one of the power steering hoses removed from the rack using a slide hammer, but the other is stuck fast and there is no way it's coming out.

So, a couple of questions for anyone...

1. Does anyone have any advice for getting these hoses off of the rack (these are the supply and return hoses)

2. Does anyone know where I could purchase new hoses if required? I've checked Design 911 but I can't find them on their site.

This job has grown arms and legs!

Joe
 
  
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Paynewright
Trainee


Joined: 17 Apr 2018
Posts: 60
Location: Nr Lutterworth Leics


PostPosted: Sun Apr 22, 2018 5:55 pm    Post subject: Reply with quote

There is a good picture on the RPM website showing the subframe hanging down at the front with steering column disconnected. All the pipes seem exposed / accessible.

Ian
 
  
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joewhite2417
Trainee


Joined: 09 Jun 2015
Posts: 53



PostPosted: Sun Apr 22, 2018 7:05 pm    Post subject: Reply with quote

Cheers Ian. I saw that! Too late now as I've started disconnecting the rack, and the one of the connections has seized part of the way out. I can't get it out or back in. I think I'm going to have to bite the bullet and either get a mobile mechanic out, or get the car towed to a local garage. I don't want to risk damaging the pipe as I can't seem to find one to buy online.

All in all, it's a bit of a nightmare, and it was all going so well!

Joe
 
  
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wasz
Magny-Cours


Joined: 28 Dec 2012
Posts: 2643


1999 Porsche 996 Carrera 2

PostPosted: Sun Apr 22, 2018 9:02 pm    Post subject: Reply with quote

Nooo! Can you not get the lines back in? Those are long and very expensive new.

You may be able to get a local hydraulic hose engineer (PIRTEK?) to make up new ends for you.

AFAIK my mechanic dropped the rack off the column and left the lines connected.

Usually the best way to tackle the nuts is to cut the crusty hard line off and used a well fitting socket on the flare nuts.

This makes it look so easy:

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My special order Vesuvious Charcoal 996 | Clutch, Fly RMS IMS AOS Job |
Steering Rack Hard Lines | Air Con Compressor / System
 
  
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joewhite2417
Trainee


Joined: 09 Jun 2015
Posts: 53



PostPosted: Mon Apr 23, 2018 8:22 am    Post subject: Reply with quote

That looks like a C4... It looks like the transfer box is being held up with that chrome pole. I will have another try of getting the lines back in. Tapping them in with a punch may help, and Pirtek is another option. I have a spare rack that I could take over to them to see if they could get something to fit.

Cheers for the advice.

Joe
 
  
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Paynewright
Trainee


Joined: 17 Apr 2018
Posts: 60
Location: Nr Lutterworth Leics


PostPosted: Thu Apr 26, 2018 7:29 pm    Post subject: Reply with quote

Joe,

How is it going? Picked my pipes up in person from the power steering store on Wednesday and will tackle when I do the front suspension refresh.

Ian
 
  
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Paynewright
Trainee


Joined: 17 Apr 2018
Posts: 60
Location: Nr Lutterworth Leics


PostPosted: Mon May 21, 2018 5:06 pm    Post subject: Reply with quote

Any update - I’m just tackling mine and its challenging! Got 3 of 4 pipe unions undone with it in situ but the last one is resisting due to access!!
Ian
 
  
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