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Power Steering Rack Replacement <pic heavy!>

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  • Power Steering Rack Replacement <pic heavy!>

    Steering rack is pooched, so I suppose it's time to replace some other bits while I'm in there...



    Probably won't install the used ball joints, mine look okay so far. But the timing belt kit, tie rod ends, strut/motor/trans mounts, snub mount & bracket, phenolic intake manifold spacer, valve cover gasket and oil pan gasket will all get installed. I'll have a look-see to figure out if the aero-wipers I scooped off my A4 will work; if so, that'll be (.)(.) because the stockers don't apply even pressure over the span of the blade (so it lifts in spots).

    I ordered a pair of strut mounts some time ago and never got around to installing them. So I ordered another pair of the same ones since I'll be replacing them right away. Well 034 must have changed specs because the new ones are clearly different than the ones I already had on hand.

    (Old ones are on the outside, new ones are in the middle)




    Does this depth discrepancy strike anyone else as being odd? Any ideas?

    Upon inspection, my harmonic balancer appears to be shot. The rubber has rotted out in some spots, not a nice sight. According to 034 the FluidAmpr needs to be shimmed for proper fit so I held off on buying one for now in the interest of getting back on the road ASAP. Hope this doesn't come to bite me in the ass later.



    Of course, broke a few parts and tools along the way. On a car this old, carnage is assured. Count so far: one spark plug wire, one fuel rail bolt, two downpipe studs, and three screwdrivers.




    This A/C hose bracket destroyed three screwdrivers before I clued-in that a combination wrench may perhaps be the proper tool.

    Carnage:


    This is where the exhaust meets the downpipe, can you say corrosion??? The two visible bolts ended up getting busted off, likely because some meatball wrenched as hard as he could. Of course, the difficult to reach far-away bolt (not shown) came apart with no drama.


    One thing I'm really looking forward to is deleting the corroded beyond hope aux. radiator, and upgrading the snub mount and bracket. I have a feeling the new poly and mount will lend a noticeable difference.




    There's lots of little pins and sensors to disconnect with this car, so I've just been progressively taking pictures to reference later as I go along...



    But just about everything that's similar size is colour coded anyways, so it's pretty hard to mess up when time comes to reconnect everything.

    Which brings us to where I'm at right now:


    Hung up on removing the trans from the engine, looks like I need some super short swivel tool or something to remove the bolts. (They're M10 hex/Allen head bolts) Any tips/tricks/experience would certainly be appreciated!!
    Find me on Instagram @pry4sno

    Candy White 2010 VW Golf Sportwagen TDI 6 speed /// #farmenwagen
    Indigo Pearl Effect 1992 80q 20v /// Eventual AAN'd Winter Sled
    Brilliant Black 1990 Coupe quattro /// Because Racecar

  • #2
    Re: Power Steering Rack Replacement <pic heavy!>

    How bout dropping the sub-frame to get at them
    I may appear to be nice, but don't be fooled, I probably don't like you

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    • #3
      Re: Power Steering Rack Replacement <pic heavy!>

      nice workbench/shelves !

      Comment


      • #4
        Re: Power Steering Rack Replacement <pic heavy!>

        Originally posted by Ryan View Post
        nice workbench/shelves !
        Haha, that's the first thing all my friends say when they come over. Not much room to get a lot of work done in this garage so my Dad went all out buying these ones so as to maximize the work area. He says thanks!

        Originally posted by Mantis View Post
        How bout dropping the sub-frame to get at them
        Ended up getting schooled in the trade when Mike showed up to help. Apparently it's not his first try up to bat...

        Engine's out:


        Just so I can replace this:





        PWNED!!! Can't remove the right bolt on 12/13. (^^^^ Shows the left)


        Will probably need some kind of stubby ratchet wrench, possibly one with a hinge at the box end. Observe:
        Find me on Instagram @pry4sno

        Candy White 2010 VW Golf Sportwagen TDI 6 speed /// #farmenwagen
        Indigo Pearl Effect 1992 80q 20v /// Eventual AAN'd Winter Sled
        Brilliant Black 1990 Coupe quattro /// Because Racecar

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        • #5
          Re: Power Steering Rack Replacement <pic heavy!>

          wow that is a lot of work! koodos dude. Is that on the 1990 coupe? too bad they hid it in so well. i know on my B5 the rack slides out through the wheel well. nice work space!
          D.J.
          Turbo SVT Focus
          Audi S4 Stage 3++++++

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          • #6
            Re: Power Steering Rack Replacement <pic heavy!>

            Nice work! You finally dove in!
            ~Chris[/FONT]

            [FONT=Arial]
            '10 Quartz Grey S-Line Avant 2.0T
            '05 Brilliant Red USP Avant - 1.8T 6MT
            - gone

            "The Build" My GT2871R build thread

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            • #7
              Re: Power Steering Rack Replacement <pic heavy!>

              Originally posted by aliencurv View Post
              wow that is a lot of work! koodos dude. Is that on the 1990 coupe? too bad they hid it in so well. i know on my B5 the rack slides out through the wheel well. nice work space!
              Originally posted by MmmBoost View Post
              Nice work! You finally dove in!

              Thanks guys, yeah it's a lot of work but once it's done I shouldn't have to bother for another 250,000 km and by then I'll know exactly what needs doing beforehand.



              Minor victory: that bolt that previously had me pwned is now off, thanks to my new 17mm stubby gear wrench and my Dad, who is now my hero. It was so tight in there you literally couldn't fit a knuckle socket or spray weasel piss on the nut plus you're on your back stretched right out... a super tight spot indeed! Oh and it's got blue Loctite on the threads and you can't snipe it either.

              Just taking these photos with a huge lens and flash was a chore.





              Next step is removing the steering column then the rack should come out (somewhat) directly afterwards. May still have to drop the subframe a little to allow bellhousing clearance but that looks to be a bunch of extra work I'd rather avoid, regarding the SF stretch bolts, clutch slave and electric rear differential lock, etc.

              Still looking for ideas/opinions on the strut top mounts if anyone can think of anything.

              Received silicon coolant hoses and spark plug wires from 034. Going to order updated injectors, flywheel bolts (still undecided about OEM/1-time use vs. ARP/reusable), OEM harmonic balancer and OEM exhaust gasket kit w/ new hardware then the various crush washers I'll need for the PS rack & pump.

              Progress is nice, albeit slow at times. More pics as progress follows.
              Find me on Instagram @pry4sno

              Candy White 2010 VW Golf Sportwagen TDI 6 speed /// #farmenwagen
              Indigo Pearl Effect 1992 80q 20v /// Eventual AAN'd Winter Sled
              Brilliant Black 1990 Coupe quattro /// Because Racecar

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              • #8
                Re: Power Steering Rack Replacement <pic heavy!>

                Made an order with 034 to replace all the old & broken bolts/washers/nuts/gaskets (PS rack, exhaust manifold/head, EM/DP, ARP flywheel bolts, OEM clutch bolts), OEM rear main seal & gasket, 034 heater core coolant plug adapter, OEM crank pulley and 034's updated fuel injectors for this motor. They're including a pair of strut top mounts to replace the two that were apparently from a bad batch, so that ties up that loose-end.

                Motor is out.


                Mounting it on the stand was a capital b!tch, had myself and a friend stumped; eventually required an old-man trick of my Dad's, mounting solid with three bolts but using one in tension without a bolt.

                Steering wheel and instrument cluster are on the shelf. That alone is a job unto itself.





























                Intake and exhaust manifold have been removed, and the valve cover and gasket have been removed then re-covered.



                Next is the driver's knee bolster and steering column & firewall boot, then (I think) I'm free to remove the steering rack.

                Once the rack is out, I'll feel free to start cleaning before the big reinstall of everything. Any BTDT tricks/tips are always appreciated!

                Work on the timing belt kit will commence once I've decided if I'm going to pull the heads or not... which hinges on me deciding to buy ARP head studs now vs. later (when it's big boy build time). Thing I'm afraid of is getting inside the heads and then (once again) buying another thousand dollars of parts just because I'm there already. There are other facets of this restoration/project that I have in mind first.




                But rocks and sand inside my valves don't exactly muster massive amounts of confidence, either. What would you do?


                Last edited by PRY4SNO; 04-21-2011, 09:46 AM.
                Find me on Instagram @pry4sno

                Candy White 2010 VW Golf Sportwagen TDI 6 speed /// #farmenwagen
                Indigo Pearl Effect 1992 80q 20v /// Eventual AAN'd Winter Sled
                Brilliant Black 1990 Coupe quattro /// Because Racecar

                Comment


                • #9
                  Re: Power Steering Rack Replacement <pic heavy!>

                  rebuild engine!

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                  • #10
                    Re: Power Steering Rack Replacement <pic heavy!>

                    Clean out the crap and change that TB!
                    Jordan
                    Jerbel Autowerks

                    Distributor of parts from:
                    JAW, 034 Motorsport, Power Up Lubricants and OEM replacement parts
                    (403) 690-7135
                    jordan@jerbelautowerks.com

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                    • #11
                      Re: Power Steering Rack Replacement <pic heavy!>

                      ^^^ this... you're there now and a quick investigation into the crud could save you down the road. Just keep your penny pincher glasses on when you open'er up
                      Work - houzz / linkedin
                      Play - haldex swap

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                      • #12
                        Re: Power Steering Rack Replacement <pic heavy!>

                        Ya its really coming along dustin!
                        I didn't even know you were having problems with mounting the engine till I came by and you had it done already. You should have called me we would have figured it out
                        Custom Built Single Turbo S4

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                        • #13
                          Re: Power Steering Rack Replacement <pic heavy!>

                          good work!

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                          • #14
                            Re: Power Steering Rack Replacement <pic heavy!>

                            cool thread bro. nice pics to document.
                            Jess

                            2010 Jetta TDI 6 SPD - Stock Comfortline model

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                            • #15
                              Re: Power Steering Rack Replacement <pic heavy!>

                              Thanks again to Colin for the help, feel free to buy tools and then need to test them out any time! Look out Rondal... floater has the pimped B5S4 roadside kit, complete with spare parts and fancy 17mm wrench!

                              Steering rack is out, required disconnecting a couple ABS brake lines and another couple brackets in addition to what I'd initially expected.


                              At the back of the rack are the supply/return fittings, and they were absolutely the hardest connections I've ever had to break, I swear. How we didn't break the banjo bolt with both of us reefing on it with everything we could muster I will never know. I busted two going an 1/8th turn past wrench snug when I previously replaced the steering pump, so I was a little paranoid but it held up fine.

                              Most impossible spot to work on the car, IMHO.




                              How's this going to line up for my tie rods now??!?




                              Next task is the strut top mounts, I'll work up front first.

                              Engine & bay degrease and clean. ==> what are you guys using? I'm thinking degreaser and scothbrite pads, water rinse and then a wd40 wipedown.




                              Timing belt ==> rocks in valve issue? can I blow it out with an air compressor or do the heads have to come off for inspection?

                              Reassemble/reinstall everything when my 034 order arrives.

                              Alignment.

                              OOOO

                              Find me on Instagram @pry4sno

                              Candy White 2010 VW Golf Sportwagen TDI 6 speed /// #farmenwagen
                              Indigo Pearl Effect 1992 80q 20v /// Eventual AAN'd Winter Sled
                              Brilliant Black 1990 Coupe quattro /// Because Racecar

                              Comment

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