Edit: Consensus seems to be, that if your rack has no play, leaks etc., leave well enough alone. Here is the information that I had collected anyway: Part Number for rebuild kit: 1H0 498 020 Youtube video of rebuild (ZF BMW rack): Link Workshop manual: Link Cost: €45 at VW dealership _________________________________________________________________ Original Question: Has anyone rebuilt a mk2 power steering rack? If so is there much to it, or much that can go wrong? I'm currently in the middle of a front end refresh and have cleaned up the rack ready to put back in, but I'm thinking now that I have it out, it wouldn't hurt to rebuild it with fresh grease and new seals. It is 30 years old after all.... VW classic parts have the rebuild kit for 55 euro, here
Cheers Sam. Local VW dealer was able to get the rebuild kit in for €45 and I found John's manual for rebuilding it. Part number for the rebuild kit is: 1H0 498 020 (not sure if I should link to the manuals @rubjonny ?)
We don't really have TPS here in Ireland, where myself and David (and several more) live. David, is it loose, or leaking?
I'd be of the school that if that rack is giving you no bother, then leave well enough alone. The fact that the unit has lasted that long without issue is (in my opinion) a good sign to leave it as is.
Yeah, thinking about it some more it's probably best to leave well enough alone. The last thing I need is to damage it and have yet another thing to add to my to do list.
yeah no problem linking the manual direct, its not like my google docs are a secret the job is pretty involved but the manual is pretty clear about the whole process. that said if it was ok before,. no need to worry as said earlier
is the any special tools needed to strip a power rack .ive threaded a fitting but got a mk3 rack wondering if i could put all the stuff from mk2 rack into the mk3 rack casing once its stripped down
a couple bits and bobs, pdf is here: https://drive.google.com/file/d/1-5XEzedzbBe5XXT-1cNqulQZ3CzEcjBO/view
hi ther im wanting to swop over a valve body from a mk2 rack to a mk3 rack would it be possible just to remove the valve body on its own .thanks
no sure potentially cases/valves might differ but I believe the seal kits are all the same. note that guide is for TRW rack and wouldn't work for ZF. I might be able to get the ZF one if you need it
it looks the same .problem ive got is removing that alloy cap with the 4 notches .it looks like once that cap is off its 1 nut an the circlip an that valve pulls out .how wouldbi remove that cap with the 4 notches?
Make a diy socket from another socket(looks like a 24-27mm) with an angle grinder. I did try to repair a passat b5 rack with new seal kit that was leaking. It was ok for few months after and started to leak again. Problem was the case was worn out(the rack was sitting offset), and the "rack shaft" rusted/pitted. Fitted a used one that is good today. What needs a little more attention are the teflon seals from valve pinion and center seal on the rack. Hope you understand even if i have got the mechanical terms mixed up.
