How Ford Steering Racks Are Rebuilt
A Rebuilt Ford Steering Rack – The Way It Should Be!
Stripping and Inspection
Racks are stripped and all parts are inspected for evidence of damage such as cracks, wear, scoring or corrosion. In most cases if there is too much wear to be cost effective to repair then the rack is turned into components to be used in another steering rack rebuild.
Cleaning and Measuring Wear
After stripping down the rack all parts are thoroughly cleaned with solvents and compressed air to remove old steering fluid, gunk, etc. Next all parts are measured with precise micrometers to check for ovality or taper of the rack shaft as well as for pitting of the individual pinion gear teeth. Measured values are compared against Ford tolerances for automotive components as used in the UK, similar to any new part that would leave a Ford factory.
Replacing Seals and Internal Components
The rubber seals, O-rings and Teflon piston rings are all replaced as a matter of course, whether they appear to need it or not. The bearings that support the pinion shaft are also replaced and the valve seals are replaced with new ones from a matched seal kit for that particular model of Ford vehicle.
Reassembly and Pressure Testing
The rack is reassembled with new seals that have been lubricated before being fitted to a car to prevent them tearing. The rack is then fitted to a pressure test rig and pressurised to a working hydraulic pressure, approximately 100 to 130 bar, to test all of the new seals for any leaks while under load.
Final Bench Testing for Play and Smoothness
The rack is fitted to the bench test rig in the workshop and then operated through its full range of movement. The rebuilder can then check for tight spots and any notchiness or free play at the pinion and, by altering the preload on the bearings, can ensure that the rack operates smoothly through lock to lock.
A rebuilt rack should feel just like a new one.
