Transit steering

[Boxerman]

Your steering pipework is a lot more complex than mine! I have 3 pipes - from res to pump, pump to rack and rack to res.

Top bearing looks a similar setup to the Boxer.

I should have some compressors in the shed if you're stuck PM me if you need them.

HTH
Frank

 

[Boxerman]

Alzi

Don't want teach granny to suck eggs but if your doing the top strut bearing, crack the nut (No 10 on diag) before slackening the retaining nuts (No 9 on diag) saves hassle later.
Reverse when re-fitting torque that one last (No 10)

Rgds
Frank

 

[Alzi1967]

UPDATE

You will not beleive this !!!!!!

I have been down to kent again this last week , another 700 mile round trip, not fun especialy the 8 1/2 hour trip back.

Anyway,
Sunday 1pm 25th April
Checked Oil , Water , Tyre pressure , All Ok.
Pas fluid had dropped 1" in the reserviour overnight????? Hmm
didnt think too much about this , I thought air lock and topped it up
To Max level.
3.30 pm Wolverhampton Checked Pas Fluid. Virtialy Empty.
Not i,m a bit concerned. still I had fluid with me so refilled it.
Called in to Wolves to collect something, Then set off again.
Got to M1 services (Northampton) decided to stop and check fluid. - Still full
Travelled to M25 (South Mimms services) , stopped and checked fluid , Still Full.
So carried on to Maidstone.
Arrived 8pm checked fluid - still full.

Monday 26th April
Checked the PAS fluid , It was Half empty !!!! - But No leaks Anywhere. ???
Was this an airlock or What ????
Filled it up but didnt go anywhere

Tuesday 27th April
Checked the Level in the morning , Half empty again ! this time fluid dripping
from the n/s of the front crosmember.
Filled it again - Still didnt go anywhere.
Had a thought , I hadnt changed the seals where the pipes go in to the rack !
Were these leaking (coulnt see properly)
So phoned the local Ford Garage SMC.
After 3 phone calls and 4 trips to the dealers managed to get the seals.

Wednesday 28th April
SAME Again , half empty.so went to do the seals , BUT its not them thats leaking, Whilst under
the Van the n/s gaiter on the PAS rack is swelled up like a baloon ,
obviously full of fluid- LEAKING SEAL !! NOT HAPPY !!!!
By now Im out of fluid , Trip to local motor factors £27-83 for 5lts Fluid.
Phoned Rack supplier , Their reply "All we can do is exchange it ", as expected.

Friday 30th April

Refilled PAS and set off back to Blackpool at 11 Am.
with regular stops and checks , got back to Blackpool 7.30 pm
Bank Holiday Traffic !!!!


TODAY Saturday 1st May

Starting at 7.45am
Took Rack off - Took it back.. EXCHANGED IT.

Back home 9.25am

Took PAS pump off , and pipes and reserviour all off cleaned , flushed through , blown all pipes through with compressor , and pump all cleaned blown through and flushed with clean fluid.
Reserviour washed ,dried AND blown thorough with compressed air.

ALL SPOTLESS AGAIN !! -

Refitted pump, reservioir and pipes.
Run new fluid through to flushed everything through Again
Fitted NEW rack complete with Brand new track rod ends AGAIN.
Fitted new seals to the pipes, Filled with fluid and took the return pipe off into old container and flushed it all AGAIN
Refitted the steering Colomn UJ ,
Refilled with Fluid.
Went to bleed it up.

THERE IS A SEVERE KNOCKING COMING FROM INSIDE THE RACK SPINDLE WHEN YOU TURN THE WHEELS.

THIS IS JUST UNBELEIVABLE.YOU'D HAVE TO BE HERE TO BELEIVE THIS


THIS IS THE SECOND FAULTY RECONDITIONED RACK FROM EK BRAKES IN BLACKPOOL.

AND WHEN ROAD TESTED - THE STEERING IS JUST THE SAME AS IT WAS ORIGINALLY - BUT WITH THE ADDED KNOCKING !!.

I HAVE HAD ENOUGH I DONT WANT ANOTHER RACK FROM THEM , BUT THEY TOOK MY OLD 1 IN EXCHANGE.

What do I do ???????

 

[Coolasluck]

Sorry to hear of your woes mate,through experiance and watching people cause themselves no end of costly damage by tinkering with stuff themselves i have always been under the attitude of take it to a garage and let them sort the problem.I myself have changed parts to then realise that it was something else,money spent unnessarsarily

You do appear to have had a lot of bad luck

I am wondering if it is a problem that is giving you the problems and maybe not the rack,but something else that is damaging your rack.
I take it that the rack is exactly the same as the one you took off?And not one that is for some reason very slightly differant?

 

[Alzi1967]

I Agree , If you can find a garage you can trust , I have always done my own vehicles for the last 28 yrs, I have Managed and run sucessfull racing teams and built / repaired numerous Race/ championship winning cars , plus run a number of very sucessfull workshop/garages and never had any problems like this before , thats why I put the thread on here , as most of you use van mechanical components, Ive mainly worked on cars , someone may have had more experience than me, with commercial type vehicles , and it is a camper !!

I initially started the same thread on the transit forum , but had very little response

Just My Family have travel in this , I wouldnt trust anyone else , I have seen a lot of bad workmanship over the years.

No one can fault my work , anyone is welcome to have a look and try.

Initial diagnosis of my fault on the van may have been wrong , this is due to the nature of the initial fault.

even if this thread doesnt appear that way , Its not the work thats faulty its the parts.

OR IS IT JUST PURE BAD LUCK , WHO KNOWS !!!

BUT ITS LOOKING LIKE THE BEARINGS IN THE TOP MOUNTS !!!!!!!

 

[tclarkie]

Hi There sorry to hear about your bad luck. I have been havin the same problem as you on my transit but my is a 1999 v reg. Apart from my steering is hard all the time. I got a guy to have a look at it and he said it seems like the suspension bearings could be seize or the ball joints and doesnt think it is anything to do with the compoments of the power steering system. I will be doing my over the weekend so i let you know if this solves it or not.
Hope you get yours sorted soon

 

[Alzi1967]

tclarkie "GOOD LUCK" , I would be happier to have had a permanant problem , wheas an intermittent one is very difficult to find.

Let us know please

coolasluck

Initial fault looked like pump or rack loosing pressure, so changed pump as the original one had a chip in pulley anyway, then tried rack which also had play in tie rods , so decided to change it anyway.

I have had a run of bad luck with parts arriving faulty or broken.

1st brand new Ford pump arrived with a smashed / broken pulley from supplier -

1st "Recon" rack arrived with stripped tread where pipes clamp in, which was,nt spotted till it was fitted this was bought online and sent via courier , supplier said "IT WAS NEW OLD STOCK" more like customer return.

In between fitting all new components each time the system was flushed through with clean fluid and blown though with compressed air ,

Which is probly more than any garage would bother to do ! ,
This is to reduce the possibility of contamination from failed parts..more

Ball joints/track rod ends replaced just to Eliminate them as they are relitavly cheap.(for the first pair anyway)

The First EK BRAKES rack well .only leaked whilst not under prssure , fluid seeping past the seal , wouldnt be spotted during testing, especially as it filled up the gaiter.

The latest rack fault was detected before it even turned a wheel IT KNOCKS . obviously one of the reasons why it was sent to be reconditioned in the first place.

This should have been detected whilst being Inspected by reconditioner.

I AM CURED !!!!

 

[n8rbos]

very very suspicious that'just picking summat up' in wolvo!!

my neck of the woods til 8/9 month ago lol.

so sorry ya still avin probs m8, but i'm sure you will sort it!

 

[Alzi1967]

It was actualy Perton on the outskirts of wolverhampton.

Nothing Sinister ,

just a Spare Tyre Fully tested part worn as new 9.75mm tread £35,

Not bad when you concider round our way they are £167 new

Thanks for the vote of confidence on getting the van sorted.

 

[Boxerman]

THIS IS THE SECOND FAULTY RECONDITIONED RACK FROM EK BRAKES IN BLACKPOOL.

AND WHEN ROAD TESTED - THE STEERING IS JUST THE SAME AS IT WAS ORIGINALLY - BUT WITH THE ADDED KNOCKING !!.

I HAVE HAD ENOUGH I DONT WANT ANOTHER RACK FROM THEM , BUT THEY TOOK MY OLD 1 IN EXCHANGE.

What do I do ???????

You haven't been kicking some old lady's cat have you?

Seriously, when you bought the first rack from EK Brakes, there was a test certificate on it, which you have a photograph of. Was there one with the second rack? If so you need a photo of that as well, and any other paperwork.

I can well understand that you do not wish to deal with EK brakes again but I think your hands are tied as, like you say, they have your old rack and your money.
Explain the situation to them and tell them that the racks they sold you cannot have passed the tests on the certificate and are therefore contravening the sale of goods and trade description acts.

Ask for a refund and your old rack, tell them that you have evidence to prove that the faulty racks were sold as tested when they obviously were not, the fact that they took the first one back means that they accepted it was faulty. If they can't give you your old rack back (probably sent it off for "reconditioning") ask for your money back and keep the one you now have.

Don't forget that the seller is responsible, not the manufacturer, don't get palmed off with "you'll have to deal direct with the people who supplied the rack"

Threaten to go to the trading standards officer in your area with your evidence if you don't get satisfaction (go anyway if you feel like it) I don't know if you have the same one as Preston - Jim Potts - but he is "keen".

From what I have read here about your abilities, I am in no doubt that the problem is down to faulty parts rather than your lack of skill or knowledge BUT it might be an idea if you can have a word with someone from a Ford agent who works on these vans to see if it's a common or known problem.

Rgds
Frank

 

[n8rbos]

It was actualy Perton on the outskirts of wolverhampton.

Nothing Sinister ,

just a Spare Tyre Fully tested part worn as new 9.75mm tread £35,

Not bad when you concider round our way they are £167 new

Thanks for the vote of confidence on getting the van sorted.

bout every two weeks i'm down wolvo so if u or any1 wants owt pickin up i'm ya man ....save ya fuel
what size tyre?

 

[Alzi1967]

You haven't been kicking some old lady's cat have you?

No , But If it would help I will start !!

Hi Frank

As regards the test certificate for the second "EK" rack , then yes I have that , but no new receipt.

As far as I can see each rack has a New serial number etched into it, so there should be a record of it being changed.

As for the Remanufacturing company "AMK", their website clearly states they do NOT deal with the public , so "EK" will have to deal with it.

you should see AMK's surcharge - refund criteria for old racks. http://www.amkauto.co.uk/pages/returnstandards.pdf

Its now at the stage where I cannot absorb the additional costs incurred in replacing the rack again, as Im sure i will have top mount bearings to change somewhere down the line .

I have a friend who runs a fleet of minibuses , I'll go and see him during the week , see if he has had any similar problems , but ill keep everyone posted.

also thanks n8rbos.

Tyre is a 215 75 r16 Michelin Agillis 81 , matches the others on the van oh it was 9.66mm

I think I will be going that way again quite soon, back to kent again.

 

[Alzi1967]

SHORT UPDATE

I have been back to the supplier and told them 2nd reconditioned rack is faulty, Their reply was .
"we have none in stock we can get you another rack ", oh and "your old rack has gone now, you cant have it back."

do I , dont I accept another recon rack???

NOOOOOOO

I still have the Faulty rack , and will be returning it for a Full refund tommorow, and bringing up the fact they had my old rack, and see what they will do, if they will give me some sort of compensation/ credit for it.

I cant go through this again... so decided
BRAND NEW -NOT RECONDITIONED RACK !!

This arrived today

NO MORE RECONDITIONED FAULTY CRAP !!!!!!

Comes complete with Track rod ends , BUT NO NUTS

I think im going nuts !!

A trip to FORD , and that was sorted £2 for NUTS.

It should be fitted tommorow sometime , I WILL SEE HOW IT GOES.


I am also trying to source some good USED front shocks/springs c.w Topmounts.


But so I dont get Bored.. My next task ................. Full Timing Chain / Tensioners etc...

 

[n8rbos]

lol alzi my hats off to you!!!!!

when everyone else would be losin' their cools/heads your calm as a cucumber!(i bet ) lol

keep us posted

by the way that initial problem is definately caused by your dust caps missing off the rear offside wheel

 

[Alzi1967]

Hi Folks ,


NO ITS NOT SORTED YET !!!

Its back to square 1 ,Intermittent heavy and light. GRRRRR....

The only things left to try now are the 2 front struts / top mounts (Bought and awaiting delivery)

And possibly the steering colomb UJ's So Have bought another one (Bought and awaiting delivery)

What I've acheived this week are :-

Brand new Genuine FORD rack fitted c/w the new track rod ends.

Whole system Flushed Cleaned and bled through AGAIN.

The 2nd EK brakes Faulty rack returned and refunded.

Promise of my old rack to be returned.

New Tyre Fitted

Received all the parts to do the Timing Chain (All Genuine FORD).

Got Timing locking pins .

Tracking Done .. Again (Free after I explained what was had gone on).

So will see how it all goes , I dont think Ive missed anything.

Thats it for now

P.S. Could I still have missed anything ??????

Dustcap ?

 

[Alzi1967]

ITS WORKING --ALL SORTED - Yipeeee

YES ITS ALL WORKING ,STEERING ALL SORTED after ONLY 5 WEEKS

IT TOOK 5 HOURS TODAY

NOW I'M REALY PI**ED OFF !!

For all who have followed this thread !
Van Has had all of the below fitted.

Brand New Steering Rack.
Brand New P/S Pump.
Brand New Track Rod Ends.
Brand new Bottom Ball Joints.
2 USED but Vgc Shocks & Springs.
USED but Vgc Steering Colomn.
Tracking Done.

AND NEEDED NONE OF THEM !!!!!

It was :- ITEM Number 12

This part is bolted to the floor ,and is in a compressed state ,clamped between 2 plates to the floor.when fitted.and the bearing inside was full of crap.It was only when actually changing the colomn did it need to be removed from the van.

Even when I first stripped the original colomn down this didnt need to be removed.I had checked it was free when changing the Racks , and when not bolted in place it did spin freely !

This was Virtually Impossible to detect

Anyway Its All been overhauled ,
At least I Know Its all done, and steering is Perfect (Its Lighter than our Ford Focus Now)

A BIG Thankyou to all who contributed.

I Think the bearing just needed cleaning

This has been a very stressfull very very expensive excersise

TIMING
CHAIN
NEXT !!
​

 

[vwalan]

glad you found the problem.. shame it was so much work. i have never worked on transits dont like them. but it was interesting following the story. i couldnt help with advice but have learnt something. hope you dont have too many probs with the van for a while.

get a vw much better. actually i drive a mitsubishi canter and a mazda bongo .but never mind.
thanks for the tale alls well that ends well. cheers alan.

 

[Boxerman]

Sorted

Glad you got it fixed mate - it's been driving me daft and it's not my van!
Are you still going to replace the struts? personally I'd leave it as it is - just in case....

Rgds
Frank

 

[Alzi1967]

I changed the struts/springs yesterday(all off a 2005 van) , Then tested the van , They made no difference to the steering at the time, But they are in a lot better condition.

My last job to try was the colomn.

Because it was a complete one that arrived (from a 2005 van) , this is when I found that stupid piece of rubber ford crap SH*T thing that was the fault !.

CHEERS FRANK.

 

[maingate]

Go and have a lie down alzi.

You have earned it.