Fitting steering rack to the T5 1.9

[Algypan]

The cursed T5 has struck again. Ok, rack has to come out as the rack seals suddenly let up and you can imagine the mess it made once I removed the boots.

I had a recon one delivered today but I'm unsure how to know if it's lined up on the input shaft. A search online seems to show someone marking with tipex a line to mark the input shaft before removing the bolt that holds the input shaft into the steering collum. However I don't exactly understand what they are lining up? Or if it is relevant if a new rack is going in as obviously the mark isn't on the new one. A look at the rack shows this (refer to pic).

The arrow circled in red doesn't seem to be aligned with the shaft circled in blue. Is it suppose to be? Am I suppose to somehow turn the shaft to align it somehow? God knows. I don't want to install it and the steering is all messed up. (I know I will need tracking re-done).

The haynes is a bit vague with this also as includes no pics for reference.

 

[PhillH]

Can you measure your existing rack ends before it is removed? Chock your steering wheel so it can not move once the pinch bolt is removed and set up the new rack in the same way and refit.

 

[Algypan]

Can you measure your existing rack ends before it is removed? Chock your steering wheel so it can not move once the pinch bolt is removed and set up the new rack in the same way and refit.

I currently have the steering lock on, will that be enough do you think? I made sure to have it on before I jacked it up and took the wheels off and took off the outer tie rods.

 

[PhillH]

Yes it should be providing the pinch bolt is accessible and you can get it out otherwise it might be a case of taking the steering lock off, move the steering column so you can get to the pinch bolt and then lock up again

 

[Algypan]

Yes it should be providing the pinch bolt is accessible and you can get it out otherwise it might be a case of taking the steering lock off, move the steering column so you can get to the pinch bolt and then lock up again

Forgive me if I sound stupid, but wouldn't that make the steering wheel out of alignment if I have to move it to gain access to the bolt and move it again to re-align it to the new shaft in the rack?

 

[PhillH]

No you are right, that’s why I mentioned about taking measurements so the new one is fitted the same if the wheel was turned at all. From memory if the wheels are facing forward then the bolt is accessible and removable.

 

[Dundee_Kev]

Get a pair of grips on the new racks pinion and rotate to full lock. Once there, go full opposite lock making sure you know how many turns it takes and then turn it back half that amount. You don't want to install the rack with it one turn out as you'll break the clock spring once you turn the steering.

And as @PhillH says, if it doesn't line up just unlock the steering and rotate it the little bit to line up.

If the wheel is off centre a little, the wheel alignment will take care of that

 

[Algypan]

Ok, little update. That rack was not nice to get out, dreading it going back in.

I have measured the inner tie roads to around 26-27cm each side of the new rack and the dimple in the input shaft almost lines up with the arrow on the rack. Hopefully when I offer it up I will only need to unlock the steering wheel and give it a little turn to get it in. Hopefully that makes sense?

Also, seeing as I was feeling brave I thought I would clean out my steering fluid reservoir (has fragments in) and replace the pump also. While trying to remove the hex pulley bolts made of marshmellow on the pump, I proceeded to make an absolute mess of them. I mean... they are barely recognizable as bolts at this point. That'll teach me, eh! So I went to VW and ordered another pulley and bolts, but turns out I can't even remove the pump as the bolts that hold it in place are behind the pulley.

You actually can't make it up sometimes...