How to replace steering rack

kenbw2 · 2021-10-08 22:52:56

What you'll need:

- Replacement steering rack
- Possibly new track rod ends (if they're rusted on and perished like mine)
- Spanners and sockets of various sizes
- 2 litres of power steering fluid

Things to note:

- Mine's the XUD9 1.9TD. I assume it's the same for the DW8/HDi
- I gather the rack can be either have threaded holes for bolts, or plain holes, Mine was the threaded one
- We didn't need to drop the subframe, but we did need to move the engine/gearbox forward

This gives a good overview: https://www.youtube.com/watch?v=eWR9JtFSULE

Take the two front wheels off

Remove the plastic wheel arch protecty sheet things

You should see the engine, fan belt etc on one side, gearbox on the other side. Behind there is the rack

Move the driver's side subframe brace bar

There's a vertical bar that goes from the subframe to the body above.

Undo the top one completely, loosen the bottom one. It'll then spin out of the way.

Remove the track rod ends

They're at the back of the wheel knuckles, with a ball joint on the top

Undo the nut on the bottom of it, and hit the bolt with a hammer. They should come out the top.

Note where the locking nuts are on the rack. You'll need to know this for tracking it on the new rack.

Undo the locking nuts on the rack, and spin the ends and nuts till they come off.

Undo the two power steering pipes from the rack

You can access this from the driver's side through the wheel arch, circled in red below

One is 19mm, the other 17mm. You'll need an open ended spanner, and a short one will make it easier but it's doable with long ones and lots of patience

Remove the steering column from the rack

Circled in green above, it's a 16mm nut (I think). Undo the nut, then knock the bolt out

It'll be easier if you orient it such that the gap faces the passenger side

Undo the two main bolts from under the subframe

There are two 21mm bolts set in a recess in the subframe directly below the rack. Undo them, taking the long 105mm bolts out

Get more access by undoing the gearbox mount

Stick a jack under the gearbox, then undo the three bolts in the mount circled red.

The green one looks like the obvious one to take off, but it doesn't lower enough to give you the room.

Once these are off, slowly lower the jack, the gearbox should drop and slightly move forwards.

Wiggle the rack out from the passenger side

It probably needs two people to do this, one from each side.

Basically, it slides out, manoeuvring around all the obstacles. Lots of "rotate clockwise" to get the steering column attachment around things.

There's a plug of some form in the back of the gearbox. Watch you don't pull the wire out.

Refit in reverse

Pretty much the same on the way in. Watch you don't knacker the pipes on the rack.

Slide it in, bolts in the subframe, column onto the universal joint, the two supply pipes.

Refit the track rod ends, using the distance you noted when you took the track rod ends off

Finish up

Refill the power steering reservoir, then remove any air by turning lock-to-lock multiple times, refilling the reservoir as needed

Go get the wheels tracked and you should be done

Last edited by kenbw2 (2021-10-08 22:57:58)

vaz2121 · 2021-10-09 13:58:47

I take my hat off to you and your brother for tackling this job and pausing to take photos ...............
It's not a job I'd relish to do on any vehicle.....................
And would avoid like the plague ............

WELL DONE ! .............

kenbw2 · 2021-10-09 14:21:46

Normally I would have just got a garage to do the job but I was faced with a week or two without an alternator - not a great prospect when I'm so dependent on the van so my brother's infectious confidence convinced me big_smile

Not gonna lie, it was stressful but only because we had all the foibles. I'd 100% do it myself again now that we've worked out things like moving the gearbox

Pathfinder100 · 2021-10-10 19:42:33

Congratulations and sweet write up.

This looks like one of those jobs that no one wants to attempt. How many hours did it take you to do it all?

kenbw2 · 2021-10-10 20:44:24

Probably about 6 hours in total, but there were lots of setbacks we wouldn't have a second time. I reckon 2 hours to do it again

Casper · 2021-10-10 21:44:00

Six Hours yikes

Funny thing as my Turbo went last Monday and could not swap them over till the Wednesday. Mate came round at 10 and an hour in we had not even took a bolt off yet as its all rotten fixings being older vans. Had i had a new downpipe with cat i would have cut the old one out and did the job in two hours but as it happens it took us about six hours also. In our defence that was going away and hunting for the ramps. Stopping to chat to passing neighbours. Having a laugh and taking it a fast test run to piss off cyclists as i never flushed out the exhaust or intercooler. Clear now though big_smile

Funny as we got asked to do a steering rack on an Iveco Daily last month. Mate never wanted to do it but like my Maxus it looks easy as bigger the van the more room you have. Its all bolted to the front sub frame. Mate never wanted to do the job as if old bolts start to snap an easy job soon turn into a pig due to all the drilling out of old bolts and sourcing others the right size.

vaz2121 · 2021-10-11 01:31:49

kenbw2 wrote:

Normally I would have just got a garage to do the job but I was faced with a week or two without an alternator - not a great prospect when I'm so dependent on the van so my brother's infectious confidence convinced me
Not gonna lie, it was stressful but only because we had all the foibles. I'd 100% do it myself again now that we've worked out things like moving the gearbox

It's a totally doable job I just don't relish doing it at all when racks so deep down in a vehicle and are a real PITA to do......................

I start to getting cuffufled with gear boxes and getting my head around the workings of Cogs and follow whats ther[....................

Also the wiring loom of a vehicle and figure out problems and without a help guide/Map to follow circuits ... it's all a bit black magic/art to me and get my head around...........

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#1 2021-10-08 22:52:56

How to replace steering rack

#2 2021-10-09 13:58:47

Re: How to replace steering rack

#3 2021-10-09 14:21:46

Re: How to replace steering rack

#4 2021-10-10 19:42:33

Re: How to replace steering rack

#5 2021-10-10 20:44:24

Re: How to replace steering rack

#6 2021-10-10 21:44:00

Re: How to replace steering rack

#7 2021-10-11 01:31:49

Re: How to replace steering rack

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