Chris Lockhart

OK, here's the deal:

I installed the new rack, new p/s lines, filled the reservoir to the
brim, let her idle a minute, cycled the wheel back and forth, refilled the
reservoir, and repeated until it maintained full level. Went out to test
drive, and now it feels smooth as glass in a left turn, not so smooth dead
ahead, and like a tin can full of gravel to the right. Does it just need
more cycling/bleeding in the lines, or does this sound like a bad rebuilt
rack???? I don't know a whole lot about the internals, but it sounds to me
like it's an internal issue with the rack. Pump was pumping fine before rack
replacement, and with the given symptoms, I don't feel that it is suspect,
but if I'm wrong please tell me. Any and all help is much appreciated, as I
REALLY want to drive my car again!!!!! It's been almost 4 weeks since I
parked it for all this work, and it's my daily driver. Been having my wife
drive me to work!!!! TIA,

Chris Lockhart

BTW, it didn't take me 4 weeks to do the rack. I did t-belt/water pump, new motor mounts, steering rack and all new p/s lines during this period. All while trying to work one handed as much as possible, due to just getting the cast off my right wrist.

WallyP

Chris,

If it isn't the rack, another possibility is misalignment or binding in the column U-joint.

2V4V

Chris,

Missed the failure of your last rack. What happened? Curious as to if it was just a leaker, of you had a pump failure or it ran dry or what?

If you had anything other than a leaky rack, I hope you replaced the p/s fluid resevoir - it has a "filter" element in it, and is uncleanable, so any contamination would eventually be transferred to the new rack.

Though hopefully, Wally's idea is correct. Or that you got a warranty with the rack anyway.

Greg

Eric G

I'm assuming you did an alignment afterwards?

Erik - Denmark

Chris,
Here some ideas:
1. Are you 100% sure you placed the oil pipes at the right place?
2. Try to lift the front start the engine and turn l/r (several times, full turn - to stop bought sides) - If it is also here sound like 'gravel in a can', then search for the sound/reason
3. Air in hydraulic oil can make an awful sound - I.e. if you forgot to tighten the spanner around the suction hose from reservoir to the pump

John Veninger

Long shot and don't know if it's even possible, but did you install the tie rod ends in the right direction?

Chris Lockhart

Wally, I did have some issues getting the bolts to line up properly on the U joint. Never had that happen before, but then again, the one I'm used to was my old rack. I'll check that out ASAP. Thanks.

Gbyron, the rack was a leaker. Both ends failed at about the same time. And no, I didn't change the reservoir. Might be a good idea though, just because it's 14 years old.

Eric, no alignment yet, because it's not currently healthy enough to make it to the shop. Alignment should not be much of an issue though, as I did not disturb the adjustment of the tie rod ends. I'm sure it's a little out, as there are bound to be differences between the racks, but no adjustment points were altered, and with the centering bolt installed, the wheel is straight and true.

Erik, I'm *pretty* sure I got the lines on correctly. Good idea to go check though. I had a few responses from the e-mail list that felt that I still hadn't gotten all the air out of the system yet. I'm going to keep trying.

John, I was very careful with the tie rod ends, to make sure I didn't swap left for right, just because of alignment issues. Other than that, they're pretty much idiot proof.

Thanks for all the replies. You guys have given me some good ideas on where to start troubleshooting this issue.

Chris Lockhart

OK everyone, thanks for all the help and advice. Turned out that it just needed more cycling to bleed the air out of the system. I put it up on jackstands today and fired her up, and cycled it for awhile. She's smooth as glass now. Thanks again for all the help.

Ed Taylor

Good news Chris. I was about to plan a trip to Greer to work the suicide watch.

Erik - Denmark

Chris,
Good to hear - Thanks for the feed back

hupp

While on the subject of the steering rack:

I recently replaced my power steering supply hose -- it was a leaker. Install went good, refilled reservoir, cycled several times, filled once again. No more "gravel in a can" noise, but a small "hum" remains. I did not notice the hum before replacing the hose -- am I just being paranoid, or is this normal?

Erik - Denmark

Hupp,
That's not normal so you must be paranoid, but don't cry, that's a part of the pleasure of being a 928 owner! /

If the 'hum' was not there before, that can only be due to air - Did you check the spanners around the supply hose from the reservoir to the pump?

hupp

Erik,

I did not check the spanners, in fact, the supply hose was not disturbed during the project (as I incorrectly stated). The pressure hose (from pump to rack) was the one I replaced.

BTW, no more leaks so at least I have achieved partial success.

Chris Lockhart

Thanks Ed!!!!!! Glad I don't need it now. I still have some small issues after all the maintenance was completed, but they are easy fixes that I just need more time to get to. Biggest one is that since the replacement motor mounts are just a wee bit taller than stock(with shimming), my right exhaust header (MSDS) 3 bolt flange is contacting the forward mount bracket for the heat shield. We clearanced it some last night, but it still contacts during WOT, and really *hammers* the bracket. This is a bit disconcerting, but until I can get back under there to trim it out, I'll just stay outa the throttle. I do have some minor binding in the steering u-joint, and will have to remove it and re-align it. Minor issues though, given how far apart I had this thing torn down. And one handed at that!!!!!!!!!!!

BTW, I'm still looking at doing a Dyno Day, but will probably not be holding it on the 18th. You're still definitely invited to come up for Eurofest if you're interested in a short day trip.