Power Steering Rack Rebuild

Overview

This procedure guides you through resealing the power steering rack on your Porsche 944 S2 with the 3.0L engine. Rebuilding the rack yourself can save money compared to buying a rebuilt unit, and it addresses leaks by replacing worn seals. It’s a detailed task that requires a clean workspace and patience, but it’s manageable for a DIY enthusiast with mechanical experience.

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Tools Required

• Metric socket set (various sizes, including 10mm (3/8 inch))
• Long socket extensions
• Small pick (dental pick recommended)
• Hammer
• Punch
• Needle nose pliers
• 6mm Allen key
• Vise-grips (optional, for stubborn bolts)
• Various sized sockets for seal removal/installation

Parts Required

• Power steering rack seal kit (944 347 015 00)

Required Additional Procedures

Steps in these procedures are required to complete this process:

• Power Steering Rack Replacement

Step-by-Step Procedure

Step 1: Remove the Steering Rack

1. Follow this link to ensure this step – Power Steering Rack Replacement – of the process is followed accurately to remove the steering rack from your Porsche 944 S2.
2. Set up a large, clean workspace with plenty of clean rags or paper towels. Lay out the seal kit on a strip of paper towels to match seals as you remove them.

Step 2: Remove the Hard Lines

3. Place the rack on your workbench. Use a 6mm Allen key to remove the hard lines from the rack. These bolts can be tight—use vise-grips if one is stripped.
4. Replace the four rubber o-rings (two per fitting) from the hard line connections with new ones from the seal kit.

Step 3: Separate the Rack Components

5. Use a hammer and punch to remove the locking collar that holds the two halves of the rack together. Unscrew it and slide it back on the bronze steering sleeve.
6. Separate the bronze steering sleeve from the gray control tower.

Step 4: Disassemble the Control Tower Top

7. Remove the rubber boot from the top of the control tower around the spindle.
8. Remove the three 10mm bolts from the top of the control tower using a 10mm (3/8 inch) wrench.
9. Carefully pry off the top. Note the wiper seal’s orientation (groove inside, flat side out) and replace it with a new one, along with the o-ring.

Step 5: Remove the Steering Gear and Rod

10. Hold the steering gear where the steering shaft connects, turn it counterclockwise, and pull upward to slide it out of the control tower.
11. Pull the steering rod out of the control tower. Keep spacers and bearings in their original orientation.

Step 6: Replace Steering Gear Seals

12. Locate the four hard plastic rings (originally white, new ones are blue) on the steering gear. Use a pick to remove each, revealing a rubber o-ring underneath.
13. Replace each o-ring and plastic ring with new ones from the kit.

Step 7: Replace Control Tower Bottom Wiper Seal

14. Remove the wiper seal at the bottom of the control tower. This is tough to extract—use a pick or destroy it carefully to avoid nicking the metal casing (nicks can cause leaks).
15. Install the new wiper seal with the groove facing upward (toward the top of the tower).

Step 8: Replace Control Tower O-Rings

16. Replace the large o-ring in the groove on the passenger side of the control tower.
17. Replace the smaller o-ring from the shuttle’s end, next to the white spacer.

Step 9: Disassemble and Reseal the Steering Shaft and Shuttle

18. Remove two snap rings, washers, and the seal mechanism from the steering shaft using needle nose pliers.
19. Replace the rubber o-ring under the hard plastic ring on the seal mechanism and the two o-rings under the washers.

20. Slide the shuttle off the shaft. Inside the shuttle, use a socket to remove the wiper seal and hard plastic spacer.
21. Install the new spacer and wiper seal in the shuttle (groove facing passenger side).

22. Replace the hard plastic ring and o-ring on the outside of the shuttle (o-ring on the outer side).

Step 10: Reseal the Steering Sleeve

23. Use a pick and needle nose pliers to remove the plastic guide ring from inside the bronze steering sleeve.

24. Use a slightly undersized socket to knock out the wiper seal and spacer (groove faces the control tower). Avoid using a socket that hits the stepped-down sleeve edge.

25. Install the new spacer, wiper seal, and guide ring, ensuring the seal goes in evenly.

Step 11: Reassemble and Install

26. Reassemble all components in reverse order, ensuring seals are installed correctly (groove orientations as noted) using appropriately sized sockets.
27. Reinstall the steering rack following the Power Steering Rack Replacement procedure.

Post Procedure Checklist

• Check for leaks around the hard lines and control tower after reinstallation.
• Ensure the steering turns smoothly without binding.
• Verify no fluid loss after a short drive of 5 miles (8 km).

Sources

• Clark’s Garage
• Pelican Parts
• Porsche 944 Workshop Manual, Volume 1
• Youtube