About 2 weeks ago I got the wild hair up my 4th point of contact to do my own power steering rack rebuild for my 1989 928 S4. I've never done one before, but the ability to talk myself into almost anything prevailed, so the task began. I ordered the seal and O-ring kit from Pelican Parts for $70.00, and new solid mounting bushings from 928 Motorsports for $68.00 including shipping. Then I ordered ball joints, tie rod ends, and boots as a set on E-bay from Deutschepartsusa for $99.67 plus shipping. All 3 items showed up on time, and were new parts. which I was very glad to see. Anyway, the rack came apart easily enough except for the pressed in seals. They're pretty tough to get out without special tools, but eventually they gave way to my overpowering strength. The seal kit was easy enough to install and get back together, plus for added encouragement I referenced a few threads on here that have been posted in the past. Just be meticulous with the seals and O-rings as you progress with your re-installation. For the pressed in seals, I finally got to use a seal installation kit that I bought at Harbor Freight about 3 years ago. Everything went well, and after getting it back in the car, filled with fluid, and driven a short while, there are no leaks so far. (Whew, I was hoping that I wouldn't have to do it again!!) So, for about $245.00 and a little of my own time, I now have a fully functional power steering rack in my car. It has a great feel and isn't as sloppy as before. I'm very glad I took the leap to do my own rebuild. Now it's time to get the car realigned, and I wanted to use a centering tool to help get the best alignment possible, so I made one. For any of you guys out there who might want to do the same, here's what I did. I bought a 12 mm non hardened bolt with a 1.50 thread pitch that was 3 inches, or 8 cm long (CarQuest Auto Parts about $3). The length is important to get a good centered point and to how I recommend you make yours should you feel the need. I took it to my local machine shop, and for $5 the guy put it on his valve grinder and voila, 6 minutes later I had the tool pictured here with a perfect 45 degree angled point. The bolt needs to be at least 3 inches long because if it isn't, it can't be properly held and ground on the valve grinder. Anyway, I hope the info helps anyone out there who needs either a fresh power steering rack, or a good alignment.

 

We are brothers!

Congrats on a job done well done.

 

Thank you... I now wish I would have documented the entire rebuild from start to finish so there was a complete record for anyone else to use. I didn't however, because I wasn't sure of the outcome and didn't want a progressive failure to be out here for all to see. :-) I wouldn't be afraid to do another one so I could document it now that I have some confidence.

 

Well done on rebuilding the rack - you have way more patience than I do.

For those that do not want to make a centering rack bolt the Porsche part number is 000 721 913 20 and lists for $7.

 

Cool Roger, I didn't buy one because I didn't want to wait on one to get shipped. Had the completed tool in my grubby little hand within 30 minutes of deciding to get one, and for about the same money. Plus with no shipping cost or a 3 day wait.

 

Good job on the rebuild!

-Luccia

 

Very nice, and it just goes to show you what a bit of research and patients can do.

Keep your eye open for a black 928 this summer, Marquette is on our drive to list. And by chance my rack should start leaking while there...I'll know who to look up.

Brian.

 

Very cool.
Congratulations on your ingenuity and the great outcome!!!

Dan

 

Awesome.