Servotronic Steering Rack Service.

[Error404]

did the cap with the hex on the end of your rack come off ok Stu?

I had to destroy a rack casing to get the rack and pinion out when i was looking at the quick rack GB - was totally seized in there

[4WheelDrifter]

I've not had a problem with an end cap yet. Luckily. Maybe they overdid the punch marks on yours.
I secure the rack in a vice and get a scaffold tube on a breaker bar to undo the cap.

[Error404]

surprised the cap took the force TBH, i destroyed mine with a ratchet - its only a 17mm hex key in the alloy cap IIRC

[4WheelDrifter]

A ratchet? TBH that's probably where you went wrong. I wouldn't have considered doing that. It's better to use a big bar IME, smoothly applying the torque.

[Error404]

I'll try that next time Stu, although I might have just been unlucky with the one i tried..... even after the cap head rounded out i still couldn't shift the cap with mucho heat and a massive pair of stilsons on the rim and a steel tube as an extension - I took the grinder to it in the end

[4WheelDrifter]

The good old grinder method, that'll do it. :mischeif: It's sounds like it was a stubborn one. I've been lucky so far then.

I remember dragging the workbench around with a pair of Stillsons attached to one of Bo's suspension struts. I thought the cap was really tight, until I got a scaffold tube on it. Then it came undone easy.

[mouse]

Thought it would be worth adding this section from the workshop manual here - see pdf.

I'm considering doing my rack myself too - but still trying to figure out what exactly is involved in removing and reinatalling the rack.

(pdf is from here if any one is interested in more of them: http://pdftown.com/PDF-Audi-Avant-RS...op-Manual.html)

[Error404]

Worth a mention that AFAIK there has been some issues with a dodgy batch of seal kits that seem to leak, quite a few people have had problems with them after rebuilding.

[Nickel_5000tq]

I was looking for those details last week and did not found until today , grrrrr. Finally I did mine last weekend.

Good write up.

I was not able to remove the seal under the C clip. Only the small blue one. Got the kit from Rennbay inc.

[mouse]

Has anyone who's done this still have the fitting sleeves?

I got the seal kit direct from ZF but it does not come with the fitting sleeves. . . does anyone still have these and doesnt need them?

[AndyP]

I think I still have them, PM me your details and I'll look tonight.

[Nickel_5000tq]

I got the seal kit direct from ZF but it does not come with the fitting sleeves. . . does anyone still have these and doesnt need them?

Same question for me guys. I would like to change the end seal too ...


Where did you got your seal kit Mouse ? (link)

thanks.

[mouse]

Where did you got your seal kit Mouse ? (link)

thanks.

I actually got it from a local transmission repair specialist who also rebuild steering racks - my mechanic would have sent the rack there if I was to get them to fix it. They had the kit in stock but otherwise they could have ordered it from ZF locally (http://www.zf.com.au/). but I couldn't have myself as ZF wouldn't sell direct to the public.

I also needed to give them the ZF part number of the rackrather than the Audi #. .. got it off someone here so hope its right..

[4WheelDrifter]

Worth a mention that AFAIK there has been some issues with a dodgy batch of seal kits that seem to leak, quite a few people have had problems with them after rebuilding.

That's a good point.

The last rack I did was an RS2 non-Servotronic rack, and the seal kit was on back order for a while. When it arrived some of the seal were slightly different to the ones I had done before, although the process was the same. But as a result the only rack that leaked after the rebuild.

Unfortunately I haven't refurb'd another steering rack since, or ordered any more seal kits. So I don't know if the problem is isolated to the non-Servotronic rack or if it's common to all of them.

I'll be interested in how others get on.

[A80Avant]

yes i remember. that is my rack. I still have it in greece and in november ill be there. Not sure if you would like me to send it to you to have a look at it stu