Initial Inspection and Fault Assessment
The rack is inspected prior to disassembly to check for damage, corrosion, wear and for any sign of fluid leakage. The rack is then hand cycled through its full travel to check for any sign of binding, wear, free play or excessive friction. All defects found are then assessed to determine the best course of action to rectify any problems.
Full Disassembly and Cleaning
After all parts have been cleaned, it is time to start to measure all wear parts like seals, rack bushes and pinion bearings. While disassembling, hidden damage like scoring on the rack teeth or pitting on the pinion shaft can be found. These parts are then replaced against the manufacturers’ original specifications by using precision measurement tools.
Wear Measurement and Parts Selection
Worn parts can be identified and accurately measured against the manufacturer’s original specifications. The seals, rack bushes and pinion bearings for example are typically replaced during reconditioning as they are relatively cheap compared to the rest of the rack. See also Manual steering rack..
Reassembly to Manufacturer Tolerances
Manual steering racks must be reassembled with consistent pre-load, and each fastener must be torqued to the manufacturer’s specified value. If the rack is found to have excessive play, this will increase steering effort; if it is over-torqued, the steering effort will also increase. A fresh lubricant charge is filled into the housing prior to re-sealing.
Bench Testing for Play and Travel
The manual steering rack is then put through bench testing. This test is designed to check for play and ensure that the rack moves smoothly and evenly through its full range of movement. Any signs of binding, catches or looseness detected during this test would need to be addressed prior to use on the road.
Pre-Fitment Checks
The threads, mounting points and tie-rod ends are inspected prior to dispatch to ensure that the rack is delivered ready for fitting.
A reconditioned rack should be of similar quality to a new rack and last as long.
