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that's another mess i got myself into: steering rack edition.
Alright, after 2 years of almost problem-free enjoying my '79 928, I have a not-so-problem-free month. After problems with the engine, which I could fix pretty easily, I found a leak in my high-pressure power steering hose (lucky me).
I replaced the hose today and messed up (probably earlier when I did a refurbishment of the power steering rack). When getting the banjo bolt out that connects the steel pipe to the rack, it already felt not so smooth. After re-connecting it with new copper crush rings I was very aware of the risk of threading it. It feels like it's not completely connecting, after filling it with new fluid and starting the car (to pump it around) it started leaking from the banjo bolt. I was able to close it better and better, but it still drips oil. I am not sure what my best options are. Should I just try and give it a bit more torque (I think I am really close to threading it to be honest) with another set of crush rings? Of course, I will try that first, but I was wondering what my options are.
I don't think this is something you can fix with some sealant, did anybody ever try to Heli coil this part? Or should I start saving up for a new rack...
There are definitely different thickness crush washers that you can try out first, if you're looking to test out something a little thicker. It sounds like you're worried about bottoming out the banjo bolt in the rack. I don't know about doubling them up on one side but maybe if you're desperate enough that might work.
I seem to remember Dwayne (?) recommending a slightly larger OD crush washer, as well. That might provide more sealing area, but a lower (even if only just slightly) pressure per square unit area, for the recommended torque for the bolt.
If you want to try some of these things I would be happy to send you some washers from my stash; I don't know how easy it is to source these kinds of things for you.
you can get crush washers with thin layers of some type of polyurethane....they are the bomb. they've stopped my steering and transmission line connection leaks.
Thx for your reply, its more that it doesn't seal and I don't want to put more torque on it, you know that feeling right before it says snap So I am afraid it is already a bit thorn inside. But I can try to do this, make sense! I will source some here in Rotterdam, thx for the help man!
Will try to find the post of Dwayne btw!
Don't keep tightening it. Use the bonded sealing washers linked to below.
@Petza914 you mean the ones mentioned by @Zirconocene and @mkhargrove , Right? I ordered the box here in Rotterdam, delivery is tomorrow! Thx for all the help!
@Petza914 you mean the ones mentioned by @Zirconocene and @mkhargrove , Right? I ordered the box here in Rotterdam, delivery is tomorrow! Thx for all the help!
Good news! To wrap this mess: I found the same box on amazon.nl and just put in the ring and works like a charm! Not any leaks without a lot of torque on the banjo bolt. So I think I am good to go!
THX for the help again people! For others who read this post: I would recommend using these if you ever have to work on your steering rack...
I hope Roger sees this. I don't know if he sells this type of ring or not....but I swear by them. I had a few leaks that I couldn't stop with the normal crush rings....I went as far as sanding the surfaces with 1000 grit and polishing before installing new crush rings. Nothing worked. I installed some of these and half azz tightened them and the problem was solved. I was initially worried about different types of fluids being corrosive to whatever type of plastic is on the washers, but several years in I have zero drips on transmission and power steering hose connections.
10-25-2022, 03:36 PM
that's another mess i got myself into: steering rack edition.
So I am afraid it is already a bit thorn inside. But I can try to do this, make sense! I will source some here in Rotterdam, thx for the help man! 
I ordered the box here in Rotterdam, delivery is tomorrow! Thx for all the help!
