IainM

Hi,
I'm rebuilding my rack with the KLA Industries seal kit and on initial inspection I found some corrosion on the rack:







I'm thinking that this might be OK because it's over the rack tooth portion so I'm assuming this section isn't important for sealing. What do you think? Can I just clean this up with a little steel wool or is the rack unserviceable?

pp000830

I would polish off the corrosion so it does not contaminate the fluid and with it the seals.

IainM

Thanks Andy, I'll do that.

nine9six

Polish off radially with 400 grit wet dry sandpaper. My only concern is if this portion of the rack travels through the seal. However, after cleaning up the corrosion, I don't think you have any worries.

IainM

As I disassemble the rack I see evidence of previous work:





Only the hole at 6 o'clock is machined. All else is man made.
Why are there so many misaligned half-taps (if you know what I mean)?

Am I the fourth rebuild?

pp000830

Use special WV rack grease, VW part number AOF 063 000 04. Be sure to use only VW hydraulic rack grease to lubricate the inside tie rod ends and to coat the geared rack shafts to avoid contaminating the rack with incompatible chassis greases.

IainM

The best case scenario is:
The original factory seal was with three taps. My rack has been rebuilt once but was put back together again with the cap from a different rack.

anything else is worrying. Anyone got a shot of their rack

nine'r - the corrosion is on the backside the geared part of the rack so I'm going to polish as you suggest and rebuild.

IainM

Things going nicely, almost ready to start putting the rack back together. I'm using the excellent thread:
https://rennlist.com/forums/993-foru...-tutorial.html
..and the aha moment for me was post 50/51.

I have a question on assembly. In Brians original DIY notes, he repeatedly says to put the O-ring in place and then apply ATF. Does he mean to install the rubber dry and then lube? I would have thought it would be better to lube the rubbers so they don't get nicked when you stretch them.

Is there a wrong way to do this?

pp000830

You are very brave doing your own rack as just removing the rack and puting it back in was enough for me. I sent mine out and had a shop do the actual rebuild.

Andy

rpj20000

resurrecting an old post but curious how did the rebuild fare? did you experience any leaks down the road?

IainM

It has been working flawlessly and no leaks at all. I’ll look up miles if you like but 6 years is pretty conclusive.