C5 X7 Steering Rack - Again!

[Stickyfinger]

That is exactly why I use the Marine grease....it really is very very sticky

[bobins]

Realistically, it's only the bottom inch of the shaft that needs the protection, as that's the bit that takes out the seal when it rusts.

[xantia_v6]

I know that I might sound like a broken record, but wouldn't a stainless steel sleeve on the shaft inside the seal be a better idea?

[bobins]

That'd be an excellent solution to the problem, the only drawback is that the shaft would have to come out to be machined down to accept the sleeve, and no-one on here appears to be brave enough to strip a rack down at home If I knew it was an easy job to strip the rack and - more importantly - put it back the right way, then I'd strip my spare rack down, send off the shaft to my mate who'd turn it down for me and fit an SS sleeve.

[white exec]

Could you protect this bit of exposed shaft from the elements by greasing it, and snapping a bit of smooth plastic pipe over it and coating the outside with some polyurethane adhesive (which sets to pliable 'rubber'). This might side-step the gaiter issue over the cast lump. Shaft would rotate inside the plastic sleeve, which would retain the grease.

I've never handled this component, so just trying to visualise.

[xantia_v6]

That'd be an excellent solution to the problem, the only drawback is that the shaft would have to come out to be machined down to accept the sleeve,

Not necessary, as long as the seal can be replaced from the outside. See: http://www.skf.com/uk/products/New-Mark ... leeve.html

I fitted a couple of these over the years, one to a crankshaft front seal, and one to a steering rack pinion, and they work.

[white exec]

But what if the shaft has already started to rust - presumably a rack-out job.
I was thinking about corrosion prevention, before the seal gives way.
Is that shaft just an unfortunate grade of steel, prone to weathering?

[bobins]

Looking at my picture from the previous page, I think the seals are fitted from inside the rack, and ISTR somewhere there was reference to there being two seals on the shaft.

I have a spare complete rack sitting in my shed, so if anyone wants further close up pictures of and bits of it then just ask.

[white exec]

. . . so if anyone wants further close up pictures of and bits of it then just ask.

That would be useful.

[bobins]

Could you protect this bit of exposed shaft from the elements by greasing it, and snapping a bit of smooth plastic pipe over it and coating the outside with some polyurethane adhesive (which sets to pliable 'rubber'). This might side-step the gaiter issue over the cast lump. Shaft would rotate inside the plastic sleeve, which would retain the grease.

That'd possibly work quite well. Not a lot of room to play with what with the extraneous casting getting in the way, but something might be able to be bonded into position that'd hold a reservoir of grease. It'd be useful to stick a grease nipple on it as well, but there's even less room for that

It is possible to get at the pinion shaft to lob some grease on it once the rack is fitted. Driver's wheel off, then reach in from the front and above the hub. I managed to get some spray wax onto mine the other day by using this method. There was still wax on it from last time, but I could see how the 'front' of the shaft had weathered much more than the rear.

[bobins]

Here's one I prepared earlier. It's actually of the replacement rack I fitted last year, but it shows the situation quite nicely. Compare it to the picture that I posted on the previous page and you'll see how bad things get....

Lovely rack - own work

Horrible rack - own work

[bobins]

Having had another look at the rack that Elis has fitted to his C5, I'd say that that fibre type collar is an excellent solution as it covers right down to the pinion seal. It's just a pity we don't know where Elis' rack came from



viewtopic.php?f=3&t=59741&p=571475#p571494

[wurlycorner]

Just read this one.
Sorry to hear of this going on you again Marc - absolutely terrible luck ( /design!)

And Citroen's response is typically awful.
This is the bit that absolutely gets my goat, I had the same from them about the C2;

Due to the age of your vehicle, we're unable to look into this further.

Absolutely appalling.
How new does a car have to be, for them to be remotely interested? New and still on the slow boat from China maybe? Or still on the shop floor being assembled??? Absolute crap.

If it's any consolation, from the work I've done on the C2 (and seen in some replacement used racks) there is also a definite design flaw on the racks in C2's and C3's. I will update my C2/C3 rack thread with the details when I get a mo - Guaranteed to fail, just nothing like as quickly as on X7's.
Do you know who the oem of the X7 racks is, out of interest?
The C2/C3 rack is JTekT, which is a Japanese company, so I find it very surprising they have an inherent design flaw, but there you go...

[white exec]

I'm still having difficulty in exactly visualising the positioning of that rusted shaft, but assuming the photo above shows the rack spigot poking upwards through the footwell floor, I am guessing that the rust is due to the rack and the shaft spigot being open to road weather and spray.

The link above (viewtopic.php?f=3&t=59741&p=571475#p571494) shows a gaiter seemingly fitted on the top-side, and sloping downwards to the pair of fixing studs. This might be good at keeping cabin fluff away from the spigot, and draughts and weather from coming upwards, but would do nothing for keeping weather off the rust-prone spigot and its bearing.

Would it not be better if the gaiter (or a more suitable one) were inverted, so that its narrow (circular) end was in contact with (or better, clipped around) the rack bearing casting, and its top (bell) end fitted that floor aperture? This would keep weather off the shaft. The OE gaiter could also be fitted (on to the two studs), and the 'surrounded' spigot heavy-greased.

Apologies if if misunderstand the arrangement.

[Stickyfinger]

Does the C6 have the same problem ?

Edit,
a C6 owner reports he has never seen a C6 one reported as failing in this way