Power Steering Rack Issue

[richtersand]

Hi all, after a whopping 1.5 miles of go-karting, my power steering rack appears to have failed. I upgraded to power steering via FFR so I got the KRC pump + FFR power steering rack. The boots are swollen with PS fluid I am assuming. My second go kart trip I had some steering wheel feedback and heard a lot of noise coming from engine bay. I assumed I didn't fully bleed the system so I killed engine, walked home to get power steering fluid, and topped it off. There was a little more feedback, then it went back to normal. But the last tenth of a mile steering degraded significantly. So much so that by the time I got home, the wheels were barely turning (I think harder than they would have turned with manual steering rack). I have seen elsewhere that too much pressure can cause these kinds of failures but I am assuming the pressure is right since this is the complete kit from FFR. I'll also share this with FFR but I wanted to post here to get opinions... Thanks in advance.

https://thefactoryfiveforum.com/attachment.php?attachmentid=154006&d=1633149416


https://youtu.be/qH_sf3HJQec

[rthomas98]

Can you take a picture of how your lines are ran to the pump and to the rack.

[richtersand]

Another thing to mention. I opened the top of the KRC reservoir and fluid rushed out of the top. I believe the pressure from the boots pushed back through the system.

[richtersand]

Can you take a picture of how your lines are ran to the pump and to the rack.

Sorry pics are too big. I am not sure how to make them smaller...
The top hose on the pump connects to the top/rear connector on the steering rack. The bottom hose on the pump feeds the lower/forward connector.

Top view:
https://thefactoryfiveforum.com/attachment.php?attachmentid=154008&d=1633150799

Bottom view:
https://thefactoryfiveforum.com/attachment.php?attachmentid=154007&d=1633150799

[rthomas98]

Figured would get the obvious out of the way on line routing but looks ok. Next question what size flow valve are you using? To clarify on the rack the top is the return and the bottom is the feed. But from what I can tell looks like you are routed that way

[richtersand]

Figured would get the obvious out of the way on line routing but looks ok. Next question what size flow valve are you using? To clarify on the rack the top is the return and the bottom is the feed. But from what I can tell looks like you are routed that way

Of course, thanks for clarifying. I installed KRC #4 valve, 1.18 GPM.

[rthomas98]

Looks like the rack is bad. Just wanted to make sure the ps pump wasn't creating the issue. But seems to be the same as most use it. It is just weird that both seals went. Usually it is one side or the other not both.

[klawrence]

I had the exact same issue with my new rack from FF, see my post (https://thefactoryfiveforum.com/showthread.php?40756-Ah!-thats-where-the-PS-fluid-was-going) with video. I ended up just buying one from summit as FF had none in stock. The one I got from summit ended up being a 2.5 (https://www.rockauto.com/en/moreinfo.php?pk=30774&cc=1134010&pt=7388&jsn=920) lock to lock, little touchy and may end up swapping out to the 3 (https://www.rockauto.com/en/moreinfo.php?pk=30770&cc=1134010&pt=7388&jsn=919) turn lock to lock, both of the racks that i linked will need the extenders. Hate to see it happen to someone else but I think there are some QC issues with whomever FF has building these racks.

[JohnK]

You can also buy the 3 turn rack directly from Unisteer with the extenders already installed. P/N 8010460. I don't believe it's listed on their website, but if you call you can order it.

[Jones375]

That’s odd, mine failed after about 30 miles from the left side boot. It was part of the package I purchased from FFR. I ended up draining all the fluid from the boots and disconnecting the pulley. I already had the car aligned and didn’t want to replace and get it aligned again. I don’t think FFR has them in stock to see if they would replace as the rack was one of the last pieces on my POL.

[klawrence]

so that is 3 that all had a seal leak on the left, interesting.

[richtersand]

That’s odd, mine failed after about 30 miles from the left side boot. It was part of the package I purchased from FFR. I ended up draining all the fluid from the boots and disconnecting the pulley. I already had the car aligned and didn’t want to replace and get it aligned again. I don’t think FFR has them in stock to see if they would replace as the rack was one of the last pieces on my POL.

That’s interesting… effectively making it manual steering until you get another power steering rack?

[johnnybgoode]

Just a thought but you might want to check to see if your flow control valve has been shimmed to reduce the GM type II pump's pressure down to the mustang racks required 1000 PSI. I added 3 shims to mine and it has worked fine with a Unisteer rack for several years. Just my 2 cents for what it is worth. Scott

https://www.borgeson.com/instructions/899001.pdf

154025

[michael everson]

You might only be leaking on one side, but the fluid can travel down the equalizer tube.
mike

[Jones375]

That’s interesting… effectively making it manual steering until you get another power steering rack?
Yea, I was on the fence about power steering anyways, and don’t mind the manual steering. I’ll eventually replace the rack and make it power again. Maybe in the winter when I won’t mind it being down for a bit.

[Jeff Kleiner]

That’s interesting… effectively making it manual steering until you get another power steering rack?

A depowered power rack drives horribly. Consider yourself warned.

Jeff

[richtersand]

A depowered power rack drives horribly. Consider yourself warned.

Jeff

Is that why towards the end of my drive it felt like it was worse than manual steering? It got pretty bad the last tenth of a mile…

[BrewCityCobra]

Wow, that is really unfortunate. Now I get to sit on pins and needles over the next month-ish as I wait to hook my rack up and see if I have the same problem.

[Jones375]

A depowered power rack drives horribly. Consider yourself warned.

Jeff
Hey Jeff, thanks for the warning, but can you elaborate a little more? I want to drive it for another month or so before it gets cold and rainy. Is it a safety issue or driveability issue? If it’s safety, it’ll get parked and replaced ASAP.

Thanks

Art

[Jeff Kleiner]

Hey Jeff, thanks for the warning, but can you elaborate a little more? I want to drive it for another month or so before it gets cold and rainy. Is it a safety issue or driveability issue? If it’s safety, it’ll get parked and replaced ASAP.

Thanks

Art

Not safety per-se; it'll just drive like crap with a high steering effort and little to no self centering.

Jeff

[klawrence]

When a rack is going out like this , the power assist will be hit and miss. More importantly if the PS fluid is not returning to the pump (ie sitting in a boot) it could harm your PS pump.

[richtersand]

I had the exact same issue with my new rack from FF, see my post (https://thefactoryfiveforum.com/showthread.php?40756-Ah!-thats-where-the-PS-fluid-was-going) with video. I ended up just buying one from summit as FF had none in stock. The one I got from summit ended up being a 2.5 (https://www.rockauto.com/en/moreinfo.php?pk=30774&cc=1134010&pt=7388&jsn=920) lock to lock, little touchy and may end up swapping out to the 3 (https://www.rockauto.com/en/moreinfo.php?pk=30770&cc=1134010&pt=7388&jsn=919) turn lock to lock, both of the racks that i linked will need the extenders. Hate to see it happen to someone else but I think there are some QC issues with whomever FF has building these racks.

Klawrence, am I reading this correctly that it’s only $184? Seems weirdly cheap.

If I were to shop around for a new power steering rack, what make/model am I looking for? Thanks again.

[richtersand]

You can also buy the 3 turn rack directly from Unisteer with the extenders already installed. P/N 8010460. I don't believe it's listed on their website, but if you call you can order it.

Unfortunately they don’t carry this part number any more.

[Jones375]

Bringing this thread back for a little advice.

I replaced my leaking rack with an OReillys one. The outer tie rods only screw into the inner tie rods by like 3/4”. Does that sound like enough or should I try swapping the old inner tie rods, go rack extenders, or try different outer tie rods?

[CraigS]

That is fine.

[klawrence]

Klawrence, am I reading this correctly that it’s only $184? Seems weirdly cheap.

If I were to shop around for a new power steering rack, what make/model am I looking for? Thanks again.

Yeah that is the approximate price for a reman unit with core . Cardone 22-207 is the 2.5 turn lock to lock and the Cardone 22-203 is the 3 turn lock to lock. If you order a 22-203 be sure to confirm it is indeed a 3 turn as they seem to get swapped at the reman plant. Both of the units mentioned will need the rack extenders.