Repair of the electric steering rack of Audi A4, A5, A6, A7, A8, Q5, Q7
The steering racks of Audi cars are reliable and efficient units that have a number of typical problems. As a rule, the owner learns about them through the indication on the dashboard. This is a yellow steering wheel icon on the dashboard and a corresponding message on the display. It is quite rash to think that the problem will resolve itself. Even if the error is cleared on your own, it may reappear. In the case of steering problems, the yellow steering wheel on the dashboard may soon change to red, and the power steering itself may stop working, which will lead to difficulties with driving. Therefore, when you receive a message from the car, you should contact a service station as soon as possible for diagnostics and repair.
Features of electric steering racks
If a sign of a hydraulic power steering malfunction is a fluid leakage from them, then the opposite is true for electric ones: problems begin when water penetrates the body. This causes corrosion of metal elements (rod, hinge-screw pair, bearings) and severely damages the electronics - control boards, steering wheel position sensor, contacts.
It is the tendency for moisture to get inside that is the main disadvantage of Audi electric steering racks. The problem is not unique to this brand but is common to many front-wheel drive vehicles. With this arrangement, it is difficult or impossible to relocate the steering rack and its components. For example, in the Audi A6 and A7, the control unit is generally the lowest point above the road, and in the event of even the slightest breach of the seals, problems with the electronics are inevitable.
Other models (A4 and A5) have a slightly higher rail, but not so high that in case of damage to the seals, it would prevent moisture from getting inside, especially in wet weather. All these factors repair Audi electric steering racks a highly demanded procedure that we at STS.Parts are able to perform quickly, efficiently and reliably.
How we repair Audi steering racks
The Audi electric steering rack is a very complex assembly. It consists of several parts:
- The body in which the stator of the amplifier motor is built in.
- Rotor assembly with worm mechanism and position sensor.
- The main shaft of the rail with a hinge-screw pair.
- Primary shaft with steering wheel position torque sensor.
- Electronic power steering control unit.
- Rubber seals.
Let's look at the repair process on the example of those steering mechanisms that are restored as spare parts. We offer to install them for those customers whose power steering systems cannot be repaired for some reason. For example, they have a cracked housing or critical wear. Audi steering rack restoration takes place in several stages. The very first of them, after dismantling the unit, is cleaning it in a sandblaster.
Next is a complete disassembly of the steering rack in order to defect faulty and damaged parts. We start with the steering (primary) shaft. Unscrew its cover, remove the shaft itself with the torque sensor, from which we remove the chip and wire.
Next, unscrew the end cap and remove the rotor. Check the condition of the bearing. If necessary, we bore the coupling and make it collapsible, install a new bearing.
Dismantle the steering rack control unit cover. Unpleasant surprises often await here: a damaged board and oxidised contacts. In this case, the unit has to be replaced with a refurbished one, where we replaced the moisture-damaged field-effect transistor boards with elements of our own design.
All elements must be cleaned from corrosion. If necessary, we restore the protective coating, including on electrical boards.
Apply new grease and assemble the steering rack.
Add new grease to the steering rack.
Check the performance of the unit by connecting it to a special stand.
Painting the steering rack body.
Pack the electric steering rack in a sealed bag.
We pack the electric steering rack in a sealed bag.
In this form, the refurbished unit will be in the exchange fund, waiting for a car to be installed. We are fully confident in the quality of all components, so we give a six-month warranty on the unit itself, as well as on all components and work performed. STS.Parts customers will receive a refurbished steering rack that is in no way inferior to the original part, and in some ways (for example, in terms of further maintainability) even surpasses it. And this is at a much lower price.
