Steering Rack Replacement

From THE Corrado Forum Knowledge Base

Here's the basic sequence for a G60 as I recall it, please correct me on the fixing sizes as this is entirely from memory...

NOTE... Follow Bentley manual for recommended torque settings. Use new fixings through out wherever possible. Use thread lock on everything except tie rod ends.

1. Loosen front front wheel nuts (slightly) with car still on the ground.

2. Raise the car and support the chassis with axel stands (Position them under the chassis rails) just behind sub frame / EIB and remove front wheels. Make sure hand brake is on and the rear wheels have been wedged to stop the car rolling off the stands.

3. Support the engine and box, either from above or below depending on what type of equipment you have to do this. (I used a pair of ramps, stradled with a thick piece of wood, then carefully packed it out out under the sump & g/box)

4. Turn the car's steering fully to the left and then using a ball joint extractor, break the tie rod ends free from the hub carriers.

5. With a trolly jack, support the middle portion of the front subframe.

6. Disconnect the car's battery and then remove lambda probe bracket from rear engine mount. (10mm nut on rear engine mount)

7. Remove 3 off 13mm bolts from rear engine mount (Drivers side).

8. Remove 1 off bolt from gear box mount (19mm I think). Once this is done, remember that your choosen method of engine support is the only thing seperating the lump from the floor so choose well.

9. Remove the 6 subframe fixings, 4x 20mm an 2x 17mm (again correct me if wrong but you get the picture)

10. Remove the 4x 13mm bolts securing the steering rack to the sub frame. (Again the fixing sizes are from memory)

11. Slowly lower the trolly jack, just enough to get your hand on to loosen the 13mm steering column UJ/clinch nut. (Bastard of a job)

12. Now lower the sub frame fully (as far as the front suspension allows) to expose the power steering pump hoses. (You may have to remove a plastic clip from the back of the steering rack body if it's still intact)

13. Position a drip tray under the rack and remove one of the hose's allowing all of the power steering fluid to drain.

14. Remove the remaining hose.

15. Remove the steering rack from the car.

16. Fit new tie rod ends to the new steering rack ensuring that the L/H/S is set in accordance with the Bentley manual for your tire size. (383mm +/-1mm for a G60, different again for a VR but again please check)

17. Refit all components in the reverse order with the exception of the tie rod ends.

18. Fill the power steering resevoir to the maximum mark (with recommended fluid)

19. Re-connect the lambda probe skt and then the car battery. Start the engine and feed in the power steering fluid as necessary, slowly turning the steering from lock to lock. (The pump will sound like it is about to die but this noise will start to reduce as fluid is pumped around the system)

20. Check that all hose couplings etc are free from leaks.

21. Once satisfied that no leaks are present, switch off the engine.

22. Re-position steering so that you are on left full lock and then re fit the tie rod ends to the hub carriers.

23. Re-fit wheels and lower car.

23. Take car to a garage/tire fitters ASAP and get the tracking properly re-set.

24 re-align steering wheel as it is likey to be out of centre when traveling in a straight line

Thats about it - please comment if you feel I have missed anything