TerminA8r

<center><img src="http://pictureposter.audiworld.com/13362/img_0070.jpg"></center><p>
I thought it was coming from the inner tie rod ends, but they seem fine. All the control arms seems okay too. The noise appears to be from the steering rack. After removing the rubber sleeve I can see wear on the bottom of the steering rack "rod". Metal against metal. I can duplicate the noise with the car on the lift. When I move the driver side wheel hard to the right, the tie rod pushes the "rod" down slightly and the clunk happens, (see bottom of steering rod). I it supposed to be covered in crease, like the u joints? ? This only has some grease on top and sides but none on the bottom, is that normal?
Can I force grease in to the steering rack to reduce the noise or do I need a new steering rack?

Thanks in advance for any input.

PaulW

Allowing excessive movement of the rod to hit the housing....is that what you're thinkin'?

TerminA8r

So is there anything I can do, or do I need a new rack?

icsamerica

I'd suggest disconnecting the tire rod and checking for free play.

TerminA8r

I did that, and there was no play in outer or inner tie rod.

TerminA8r

Disclaimer:
"This noise is typically from worn tie rod ends or worn control arms, check those first".

In my case it turned out to be the steering rack.

I was about to tear out the steering rack and have it rebuilt, but I went online to do some more research online and in the Bentley and found this outline somewhere.

STEERING RACK PRELOAD ADJUSTMENT

If you feel excessive play in the steering wheel, or if you hear some strange rattling or popping sounds when turning the steering wheel, or if your car tends to jump right or left whenever you hit a rut or groove in the road, there is one adjustment on the Steering Rack that may help.
(^^^^ These were my symptoms ^^^^)

There is a 18 mm bolt that sticks out of the bottom of the steering rack near where the steering shaft connects to the rack.

This 18mm bolt is the rack Pre load adjustment and it can be turned in small increments to tighten up the steering response. If you have two people available, one person can turn the steering wheel back and forth from inside the car, while the helper tightens up this Pre load adjustment in small increments until no more rattling or popping sounds are heard. Turn the bolt clockwise 1/16 to 1/8 of a turn at a time until the noise goes away and then turn it an additional 1/8 turn.

Test drive the vehicle and make sure the steering wheel returns to center after initiating a turn, if not the adjustment is too tight. Back off the adjustment slightly and road test the vehicle again.

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Further research revealed that this procedure is supported by a short text I found in the Bentley about,

"Power Steering gear, adjusting"

1. Raise vehicle on hoist.

2. Wheels in straight-ahead position.

3. By turning the steering wheel to and fro (about 30 degrees to center axis) a knocking noise will be heard if there is excessive play.

4 .The second technician must carefully screw in the adjustment screw until the knocking noise can no longer be heard inside the vehicle.

5. Carry out a road test.

6. Ensure that when maneuvering or negotiating corners the steering self-centers without sticking, re-adjust if necessary.

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<img src="http://pictureposter.audiworld.com/13362/img_0070.jpg">

I located the 18 mm bolt (it's right below the rack, you can see it in the picture) and turned it clockwise slightly (less than one turn) and the rattle went away. Unreal!!!! I took the car for a test drive over the usual spots and the car is like "new" again. I'm still beaming, I can't believe the fix was this easy. I have had this rattle for a looooong time, I always thought it was the inner tie rod, since my control arms are in good shape. I'm so glad I did not start to tear out the steering rack, it looks like a major pain in the @ss.

Cheers!!