Steering rack removal problems

drabux · 11 Aug 2015

Hi All,
I've run into a bit of a brick wall trying to remove the steering rack on my 996TT: I can't remove the high and low pressure lines from the rack. They seem to be stuck fast.

I removed the metal plate holding them in place and they seem to be lodged in the steering rack firmly. I've tried WD40, with the usual, predictable results. I've tried levering them out with 15mm and 12mm spanners around their collars, but no go. Any other suggestions? These lines are expensive and difficult to replace, so I don't want to damage them.

Cheers,
Alan

Slutters · 11 Aug 2015

Yep! Changed the lines on mine years ago, same issue, they weld themselves to the rack, try a bit of heat perhaps if your getting a recon rack.

drabux · 11 Aug 2015

Slutters,

A bit scared of heat because the plastic fuel tank is very close by as well as other hoses/pipes. How did you remove yours?

Slutters · 12 Aug 2015

drabux said:
Slutters,

A bit scared of heat because the plastic fuel tank is very close by as well as other hoses/pipes. How did you remove yours?

By changing all the pipes too.... :lol:

drabux · 14 Aug 2015

Well, an update. The pipes finally came out of the steering rack with much heat and much pulling. When I put them into the new rack, they leaked around their collars like the Amoco Cadiz. Clearly the pulling had damaged the connectors.

So, I now have both lines leaking like hell. They cost GBP500 and about another 600 to fit (subframe needs to be dropped). My plan: I've just bought a brazing kit in the hope that I can seal the awful leak that has appeared.

On a side note, the design of the lines going into the steering rack is appalling and so obviously will lead to corroded, hard to remove lines. :what:

infrasilver · 14 Aug 2015

Were there any O rings on the pipes, I'm not sure there would be as I've never removed those pipes but if you heated them up they may of disintegrated?

Chris_in_the_UK · 14 Aug 2015

The parts drawing shows the pipes as having O rings.

drabux · 14 Aug 2015

It's not the o rings causing the leak. I replaced these.

The pipe goes into the connector and where the pipe joins with the connector is where it is leaking. The cause of this was that I resorted to tugging on the pipe in order to try to get the connector out of the steering rack. I'm surprised how fragile the fitting is as well as the ridiculous way the pipe is connected to the rack. What is wrong with a banjo connection?

Brazing kit due mid- next week. Will report again then. :frustrated:

Chris_in_the_UK · 14 Aug 2015

Can you post a picture of the offending area?

drabux · 14 Aug 2015

Chris,
I'm not near the car now but here's a picture from the internet showing one of the connectors which push fits into the rack. I've pointed out where the leak is coming from. The pipe is aluminium covered in black plastic. I've removed some of the plastic in the hope I can get a decent braze between aluminium and what looks like brass.

Chris_in_the_UK · 14 Aug 2015

Hmm - I had a similar issue with clutch line which is wholly unrelated except for the fact that Porsche had chosen to use an aerospace fitting for the joints. This was a pain since the fittings were not available separately blah, blah, blah.

It would be useful to know if they have done the same for the steering lines - if they have there may be a seal inside the body of the part you posted?.

drabux · 14 Aug 2015

I suspect there is a seal, but I cannot see how I can get to it.
Brazing brass to aluminium is not going to be easy but I don't know what else to do...

Chris_in_the_UK · 14 Aug 2015

drabux said:
I suspect there is a seal, but I cannot see how I can get to it.
Brazing brass to aluminium is not going to be easy but I don't know what else to do...

I had the same - the fitting I dealt with had a section that unscrewed but there were no flats to get hold of.

The photo looks as though the end that is radiused where the pipe comes in from the left may have a seal underneath it.

I suspect trying to braze it may be troublesome (sorry - I know this is not what you want to read!) if it has a seal inside.

Have you read this related thread?

http://www.911uk.com/viewtopic.php?t=59694&sid=45f4fd1590a13ad760ec1e83054f1678

drabux · 14 Aug 2015

Chris, Thanks for that. I had already read that post. I'm going to try to solder the joint using this http://durafix.com/index.html

If it fails, I think I will buy some second hand lines with decent connectors, cut the pipes and use compression fittings to join to my current pipes. Does that sound mad?

Chris_in_the_UK · 14 Aug 2015

drabux said:
Chris, Thanks for that. I had already read that post. I'm going to try to solder the joint using this http://durafix.com/index.html

If it fails, I think I will buy some second hand lines with decent connectors, cut the pipes and use compression fittings to join to my current pipes. Does that sound mad?

TBH, no.

Had I not been able to solve my clutch hose issues I had realised it was far cheaper to use a hose specialist to make a braided one with the correct fittings. I was quoted less than £100 for what would have been £600 using Porsche parts. Thankfully I managed to sort it using a combination of the old pipe fittings and the new pipe.

Personally I would go down the compression fitting route with assistance from a local hydraulic hose specialist.

Your call mate - I feel your pain!!!

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