Power steering rack leak - advice needed

[dbo_texas]

After fixing several leaky power steering hose issues, a new leak popped up and it looks like it's coming from the rack itself where the drive shaft enters the rack (see image). I posted about this on by build thread but didn't get any comments, so posting in separate threads in the hopes somebody has either seen this before or can tell me if my PS rack is toast. My setup is a Gen2 Coyote + KRC PS setup + Forte hydroboost. On the KRC pump, I installed the #4 flow restrictor which is the smallest they make (reduces amount of assist). I've never driven the car (still building) but my kit is about 6-7 yrs old from 2018. I only recently added fluids and performed first start on the engine a couple of months ago. The Coyote/KRC setup is a proven combo, but the wildcard seems to be adding the Forte hydroboost, but admittedly I don't know much about how hydroboosts work internally. I was wondering if somehow it possibly boosted the pressure up beyond what the rack is capable of. Or, is it possible the seals just went bad over time since I only recently added the power steering fluid to the system (so everything has been dry for ~ 6 yrs). The idea of tearing my front end apart to replace the PS rack at this point is hard to swallow. So here's a list of my questions:


Is my power steering rack toast based on where its leaking from?
If yes to #1, what would be a good replacement PS rack to purchase for my setup (MKIV, Coyote, KRC PS pump, Hydroboost)?
If no to #1, is there a way to fix/repair the rack and if so, any tips/links/references on how to go about the repair? Hoping it could be something simple like an o-ring that needs to be replaced. Seems like maybe there's a seal in there that is possibly blown (either due to excessive pressure, or old age).


Any advice on this would be greatly appreciated.
https://thefactoryfiveforum.com/attachment.php?attachmentid=216483&d=1752793339

[cv2065]

I don't have a hydroboost system, but maybe it's a combo of your questions where the pressurization of the system is meeting old/dry seals in the PS rack resulting in a leak.

[dbo_texas]

Everything I'm reading online says the seals are likely blown and I'll need a new rack. Just doing some quick searching on the forums, it seems there are MANY options. I know I need a rack for fox mustang. Prices range from $150 for a remanufactured rack (as Jeff K. suggested here (https://thefactoryfiveforum.com/showthread.php?48991-Power-steering-leak&p=555220&viewfull=1#post555220)), up to +$1000. I'm definitely leaning towards NOT trying to spend $1,000. Some additional questions I have:

1) 2-3/4 turn or 3 turn? I'll be doing street driving, so I'm assuming the 3-turn would be best
3) will all the different options work with the Breeze offset bushings that I currently have installed?
3) I see many threads saying you need rack extenders....why don't you need these with the stock FFR PS rack? How do you know if you need them or not? I see Breeze sells a 1" rack extender kit. Any other sources?
4) Do the stock tie rod ends work or do you need new tie rod ends too? If so, does one size fit all or do you have to match them up with the rack?

[edwardb]

1. 3-turn usually what most use.
2. For a Fox body Mustang rack, they should be compatible.
3. FFR sources their rack with the extended length built in. If you buy anywhere else, it will need extenders. Breeze sells 1" pieces. Factory Five's are 1-1/2". Both apparently work OK.
4. The parts you have should work.

You don't have to spend $1000. In fact, that would likely be for something like a Flaming River that may not fit without modifications. Beyond the usual Fox body racks from your local parts stores, other brands I've heard good things about (not personal experience) are the BBB INDUSTRIES N1010106 (buddy has one in his Challenge car, was recommend to him by Mark at Breeze since he no longer sells the Unisteer racks I've used) and the Performance Steering Components RA-33500. I'm sure there are others. Those just happen to be ones that I've heard good things about.

[dbo_texas]

1. 3-turn usually what most use.
2. For a Fox body Mustang rack, they should be compatible.
3. FFR sources their rack with the extended length built in. If you buy anywhere else, it will need extenders. Breeze sells 1" pieces. Factory Five's are 1-1/2". Both apparently work OK.
4. The parts you have should work.

You don't have to spend $1000. In fact, that would likely be for something like a Flaming River that may not fit without modifications. Beyond the usual Fox body racks from your local parts stores, other brands I've heard good things about (not personal experience) are the BBB INDUSTRIES N1010106 (buddy has one in his Challenge car, was recommend to him by Mark at Breeze since he no longer sells the Unisteer racks I've used) and the Performance Steering Components RA-33500. I'm sure there are others. Those just happen to be ones that I've heard good things about.

Thanks this is exactly what I was looking for!

[gbranham]

I thought I read somewhere here on the forum that the offset bushings are not needed on the MkIV frame; FFR corrected that when they designed the MkIV frame. Maybe?

Greg

[cv2065]

I thought I read somewhere here on the forum that the offset bushings are not needed on the MkIV frame; FFR corrected that when they designed the MkIV frame. Maybe?

Greg

I think that is true but I installed them anyway before I knew that.

[nuhale]

3 turn fox mustang rack from O'Rielly's or Rock auto. Part number is 1010107. O'Rielly's is around $140.

Don't forget rack adapters for bump steer. I just went through chasing down a leak in my rack last weekend. I started thinking I would need a new rack but turns out it was leaky AN fitting. I used the breeze fittings and had used the washers and o-rings he includes. Please note that some racks (most fox remanufactured) have chamfers in the ports and others do not. The washers are for the ones WITHOUT chamfers which is why I had a leak.

[rich grsc]

There is no bump steer issues with MkIV and later.

[Jeff Kleiner]

Just be aware that turns lock to lock are not the 100% absolute indicators. The actual difference is the rack ratio; they'll be either 20:1 or 15:1 (FYI 20:1 indicates that 20 degrees of rotation of the steering wheel results in 1 degree change in the steering angle at the tire whereas the quicker ratio achieves 1 degree at the tire with only 15 degrees of steering wheel rotation) and although the slower ratio 20:1 is ordinarily 3 turns lock to lock some racks had travel limiters installed due to tire size which would stop the travel earlier. When shopping for aftermarket or rebuilt racks the 3 turn 20:1 ratio is usually considered "standard" and 2.5 turn 15:1 ratio will most times be referred to as being for the "performance" or "sport" suspension.

Jeff

[dbo_texas]

Thanks for the additional info here. I'll definitely be looking for the remanufactured racks. I already have the Breeze offset bushings so I plan to keep using them. Also have the travel limiters...maybe don't need those but will check when I get the body on. Sounds like I will need to buy the rack extenders either from Breeze or FFR, whoever has them in stock.

One more question for those who've done this - I don't have the body on, but do have the radiator and engine installed. Is it possible to do this swap without pulling off the radiator? I know I'll need to drain the power steering from the rack & hydroboost, but I've been there, done that so not a big deal. Just wondering if this is a couple hours to swap out, or if I'm looking at a multi-day effort.

[gbranham]

The rack is held to the frame by two bolts and tie rod ends. Add in the steering shaft removal, and the power steering lines disconnected from the rack, and that's about it. Should be an easy swap with engine and radiator in. Couple hours tops, I'd think.

[JMD]

Couple hours tops, I'd think.

HAHAHAHAHA!!!! Oh wait...you're being serious???

I've had that thought about so many parts of the build and learned to add about 50-100% to my estimate for a realistic outcome. Maybe that's just me, tho...

Plan the afternoon to be safe/realistic. Or have Greg do it in a couple of hours. :)

[dbo_texas]

HAHAHAHAHA!!!! Oh wait...you're being serious???

I've had that thought about so many parts of the build and learned to add about 50-100% to my estimate for a realistic outcome. Maybe that's just me, tho...

Plan the afternoon to be safe/realistic. Or have Greg do it in a couple of hours. :)

Haha...ok this made me laugh. Because I'm in the same boat. Seems like everything I do on this build which should take an hour or so takes me at least 2x-3x as long...always seems to turn into an ordeal. One of the first ones was getting the tie rods out of the socket when I had to rebuild the front suspension on each side. Took me FOREVER to get the thing apart...until I saw a Youtube video showing to just smack the hell out of it with a hammer. After that it took 5 minutes. I even made a video and shared it on my build thread for other noobs to learn. It's all about the knowledge and experience which is why I usually come here first.

[gbranham]

When I tell my wife I'm going out to the shop to do a project on the car, and tell her it's probably an hour-long project, she always says 'see you in 3 hours'.

I guess I should say the rack removal should take a couple of hours, as long as an hour has 120 minutes in it. :)

[Lidodrip]

I had my FFR power steering rack leak after about 2 miles of go cart runs - same place as yours initially, and then at one of the ends. Even though the rack was 18 months old, FFR was good about sending me a warranty replacement. I remember quite a few people had FFR PS rack leaks at the time. I have about 3k miles on the new FFR rack with no issues. You do not need to remove the radiator to replace it. The hydroboost system should not adversely affect the PS rack and it wouldn't over boost the pressure to the rack. KRC has plumbing diagrams that specifically address hydroboost and PS combinations - no need to worry about the hydroboost being a wildcard. Good luck with the rack replacement.

James

[dbo_texas]

Got a brand new PS rack from FFR from Paul B. (MKV build) so I'm hoping to do the swap in the near future. I already has the rack extenders so that is a bonus. I'll report back once it's installed and checked out....just need to find a free weekend.