Date:         Thu, 18 Feb 1999 11:36:48 EST
Reply-To:     Mwlf@AOL.COM
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Martin Wolf <Mwlf@AOL.COM>
Subject:      Steering rack Blues
Content-type: text/plain; charset=US-ASCII

How about that nice rebuild kit from ZF available from Bus depot.  I bought it
for 95.00 and it had all the goodies in it.  It is interesting to note that
most failures seem to be at rack ends and not at the steering u joint end.

I rebuilt mine at least a year ago and it still works.  The job wasnt too bad.
The worst part is pulling the rack off.  After that it is a bench job.
Pressure wash the rack before dismantling to keep the dirt to a minimum.  To
remove the threaded retainers on the ends I used a drift and hammer to loosen
and voila they came right out.  Record positions of parts during dissassembly
for posterity and later reference.

The Bentley actually marks all the replacement seals etc. with an asterisk
indicating that rebuild is a service operation.  For most other racks, it is a
replacement issue not rebuild.  This really made my day as it indicates the
Vanagon rack is designed for rebuild.  All the wear surfaces are inside nylon
bushings so the rack itself should be spared from wear.  Mine was nice and
shiny with no wear perceptible.  Having never been into a hydraulic system
before, it was interesting and a fun challenge which can be done in the
basement.

The sense of accomplishment looking at the rebuilt rack prior to installation
was great and the absence of hydraulic fluid on the garage floor was even
better.

Martin Wolf

85 GL