Repair of the Volkswagen Transporter T5 steering rack

Light commercial vehicles from Volkswagen are among the most popular vehicles in Europe in their segment. Models Transporter, Caravelle, Multivan, California, representing one family T5, are still not just found on the roads of Poland, but are actively used by their owners, despite the fact that the production of the fifth generation of this car was discontinued in 2015. The secret of such longevity is a successful combination of dynamics, economy with a comfortable interior, ease of driving and payload. These cars have a reputation for being very reliable machines, but, of course, the years and intensive use often take their toll. One of the few reasons they end up with us at STS is steering failure.

Typical Volkswagen T5 steering faults

If we do not take into account the failure of the steering rod lugs, which can be considered a consumable item and which should be checked and, if necessary, replaced during each routine maintenance, the main failures of steering of these cars are related to the steering rack. All T5 models are equipped with hydraulic power steering, the pump of which is driven by a belt drive from the pulley of the internal combustion engine.

That is, unlike subsequent generations of the model, the electronic component is excluded here. This unit is quite easy to operate and maintain, but is subject to a number of problems, especially in the case of significant wear. Its increase and acceleration are promoted by high mileage of commercial vehicles, roads with poor quality surface, mistakes of drivers and mechanics.

Main signs of steering rack failure:

• Leakage of hydraulic fluid

• Knocking or vibrations in the steering wheel
• Stiff or «floating» steering wheel.
• Irregular return of the steering wheel to the centre position.
• Sound when turning the steering wheel.

A real situation that happened to an STS customer is an example. He came to us with complaints about steering problems. It all started with unclear steering behaviour, which eventually developed into certain symptoms

• after parking, greasy spots appeared under the car;
• the power steering did not work «cold»;
• the steering wheel had a big backlash in the centre position;
• there was a vibration and a knocking sound in the steering wheel on rough roads;
• the steering sometimes jammed with a crunch.
• At the same time, the fluid in the power steering reservoir darkened, and it had to be periodically topped up.

Algorithm of repair of steering racks

Hydraulic steering racks in Volkswagen T5 or other vehicles are repaired in several steps:

1. Diagnosis of the malfunction. Checks the operability of the node, the presence of leaks, the state and level of the fluid. Establishes the exact symptomatology of the behaviour of the node and the car as a whole to identify the exact causes of the failure of the unit.
2. Dismantling. All protective elements (dust covers and pallets) are removed, steering rods and lugs are unscrewed. Also disconnect all hydraulic pipes. The rack is disconnected from the steering column and body mounts.
3. Disassembly. The removed rack is transferred to the repair shop. There are removed dust covers and sealing rings, dismantled stem, from the body are removed other parts: bearings, bushings, glands, etc. Check the condition of the gears, worm pair and toothed part of the rack for wear or damage.
4. Final diagnosis. A complete disassembly of the steering rack gives an idea of whether this particular unit and its components are fundamentally subject to repair, or whether its complete replacement is necessary. In case the repair of the rack is recognised as inexpedient, the client is offered two options: installation of a completely new rack, or one restored by us on our own equipment with observance of all technologies. We have a large selection of reconditioned steering racks for almost all car models in our repair stock.
5. Rail repair using new parts. In the case when the main elements are subject to restoration, a set of repair works is carried out. Depending on the nature of the damage, it may include: grinding of the rod, sleeving of the seating holes of the steering rack housing, replacement of individual elements - bearings, glands, bushings, seals.
6. Assembly and inspection of the steering rack. After repair workability and parameters of the unit must be checked on a special stand, simulating the modes of operation of the car. Under pressure, the indicators of steering torque amplification are checked, as well as the tightness of seals.
7. Installation of the rack on the car and test drive. The final stage is the complete assembly of the vehicle and driving test. After the removal and installation of the steering rack will definitely need additional procedure for setting the angles of the wheels - camber.

As a result, STS customers receive a repaired steering rack, which is not inferior to the factory part, and in terms of further repairability exceeds it. And this - at a much lower price. We are fully confident in the quality of all components, which is why we offer a six-month warranty on the unit itself, as well as on all components and work performed.