Hi folks!

I’m trying to repair my leaking steering rack,on my 2001 Octavia TDi, and remove the pinion/shaft shown here. Looking at other vids, the shaft pulls out from above, but cant get this to budge, and the bearing housing is probably/hopefully the reason.The core plug type thing on the bottom-should that lever off?

Any tips appreciated please.

Many thanks.

Looks like nobody has done this judging by the amazing response!😂, so I’ll whip the coreplug thing off, nothing to lose.👍😊

 

On 24/01/2022 at 12:56, LeGonk said:

Looks like nobody has done this judging by the amazing response!😂, so I’ll whip the coreplug thing off, nothing to lose.👍😊

 

Yeah I think most people either fit a used rack (<£50) or fit a refurbed rack (£100-200).

 

I fitted a used rack the first time mine went. Lasted ~100k miles plus whatever it had done in the car it came out of. When that one failed I fitted a refurbed rack.

 

Be interested to hear how you get on with the DIY repair to it!

The last VW rack that I refurbished was my late fathers 1982 Polo, I had a Delrin bush turned up to replace the worn one at the pinion end.

 

I cant recall how but was probably giving the pinion the good news with a hammer without having spotted a retaining circlip, I broke out the end of the casting where your core plug is, I Araldited a 10p coin over the hole and it remained like that till the end of the century when it was scrapped, the repair was done very early on.

 

Sorry that I don't know how to dismantle yours other than the pinion will certainly come out rearwards and probably be retained with a circlip, all I have had to do in recent years was an inner track rod swivel joint which initially lacking a replacement I pinched up in my 12 tonne press.

Thanks guys for your positivity 😉.

Boy what a job! I think I’m pretty good at sticking to tedious tasks.... and this is one of those thats for sure. Tried drilling the coreplug but no joy, seriously hard metal-none of my new bits would touch it!?🤔. So thought I’d weld a bolt to it and pull it off, but it wouldnt weld either. So ground the alloy around it  down until it tapped out with a hammer. Distorted the roller bearing cage on the end of the shaft a bit but hopefully still ok. Quick tap with a drift and the pinion shaft popped out!👍. Next job getting the rack out the housing-theres a circlip holding the seal/bush in the end furthest from the pinion, sprung it out with screwdrivers, removed the seal/bush and rack👍. Next job inner seal/bush.....what a bas#ard! Had to make long reach tools out of steel rod to pry it and chop it out in the end😕, buts its out👍. 

Just need to clean the rust pitting off the end of the rack, and any other blemishes, then I can start putting it back together. It will be an absolute miracle if it works!😂, but we’ll see. But the amount of time and effort is just nuts, never worth it really.

 Do any of you know if an Audi TT rack will fit? Serial number is pretty similar all but the last few didgets!?🙄😂

Brace yourselves for the next exciting episode...........😉👍

54 minutes ago, LeGonk said:

Do any of you know if an Audi TT rack will fit?

 

TT racks are a common direct bolt on upgrade for mk1 Octavias, I run one on my VRS along with the TT cast arms and hubs. Externally the racks are the same but internally they are quicker with just 2.5 turns lock to lock.

Thats good to know,

Seen a few for sale too  so thanks for that😉👍

After rebuilding the rack, the darn thing wizzed fluid out like a jetwash in the end😳. So fitted one off a TT, new rod ends, and a new wheel bearing, and boy what a difference! 😊, much nicer to drive now, and back on the road more importantly.

Thanks for your help chaps!😉👍.

yeah, i think once the seals get blown out on these racks thats it...

Last year I fitted a brand new (although still exchange) ZF K S01 001 000 from Bosch equivalent to the revised VAG number 1J2 422 063 M which was £900 + VAT trade

 

 

When I started it up it did this

 

 

 

i presyme you sorted that out Crasher?

 

at a guess the steering position sensor was out of calibration with the new rack?

Yes, I had to take another rack on my account whilst the other one went back to Germany about about 3 months later received a credit but no explanation, not a word of apology or an offer the cover the expenses of replacement... not great service; ever since Bosch took over ZF Lenk system the backup service has disappeared. It is a purely hydraulic rack so I have no idea what had been assembled incorrectly inside at least I hope it was incorrect assembly as if that could randomly happen there are a lot of Golf 4's, Octavia 1U etc on the PQ34 platform out there with a potentially lethal fault.

Edited 17 March, 20224 yr by Crasher