Power Steering Rack Rebuild – 2.5L NA

Overview

This procedure guides you through rebuilding the power steering rack on all Porsche 944 variants with an 8-valve engine configuration, covering both pre-1985.5 (1983–1985.5) and 1985.5 onwards (1986–1988) variants. Rebuilding the rack involves replacing seals to prevent leaks and restore smooth steering operation, which is critical for vehicle control and safety. This guide assumes you have mechanical experience and a clean workspace to avoid contamination of new seals.

Pink and blue text represent links to additional resources, tools, parts, and partner websites.

Tools Required

• Metric socket set (10mm (3/8 inch) and various sizes for seals)
• Long socket extensions
• Small pick (dental pick recommended)
• Hammer
• Punch
• Needle-nose pliers
• 6mm (1/4 inch) Allen wrench
• Vise-grip pliers (optional, for stripped bolts)

Parts Required

• Power steering rack seal kit, 944 347 911 00

Required Additional Procedures

Steps in these procedures are required to complete this process:

• Power Steering Rack Removal

Step-by-Step Procedure

Step 1: Remove the Steering Rack

1. Follow the Power Steering Rack Removal procedure to safely remove the steering rack from your Porsche 944. Ensure the vehicle is securely lifted and supported.

Step 2: Prepare the Workspace

2. Set up a large, clean workspace with plenty of clean rags or paper towels to prevent contamination of new seals.
3. Lay out the seal kit (944 347 911 00) on a strip of paper towels, arranging seals in order to match them with the old ones as you remove them. This helps avoid confusion, as some o-rings look similar.

Step 3: Remove the Hard Lines

4. Place the steering rack on a workbench.
5. Use a 6mm (1/4 inch) Allen wrench to remove the bolts securing the hard lines to the rack. If a bolt is stripped, use vise-grip pliers carefully.
6. Remove the hard lines, noting the four rubber o-rings (two per fitting). Replace these with new o-rings from the seal kit, ensuring proper seating.

Step 4: Disassemble the Rack

7. Use a punch and hammer to unscrew the locking collar that holds the two halves of the rack together. Slide the collar back onto the bronze steering sleeve.
8. Separate the bronze steering sleeve from the gray control tower.

Step 5: Remove the Control Tower Top

9. Remove the rubber boot surrounding the spindle at the top of the control tower.
10. Remove the three 10mm (3/8 inch) bolts securing the control tower top.
11. Carefully pry off the top, noting the wiper seal and o-ring inside. The wiper seal’s groove faces inward (toward the tower), and the flat side faces outward. Replace both with new seals from the kit, ensuring correct orientation.

Step 6: Remove the Steering Gear and Rod

12. Hold the steering gear where the steering shaft attaches and turn it counterclockwise while pulling upward to slide the main unit out of the control tower.
13. Pull the steering rod from the control tower. Keep all components (shuttle, steering rod, steering gear, control tower, steering sleeve) organized.

Step 7: Replace Steering Gear Seals

14. On the steering gear, locate the four hard plastic rings (originally white, replaced with blue in the kit). Under each is a rubber o-ring.
15. Use a small pick to carefully remove the plastic rings and o-rings. Replace with new blue plastic rings and o-rings from the kit, ensuring proper alignment and seating.
16. Keep spacers and bearings in their original orientation to avoid reassembly issues.

Step 8: Replace Control Tower Seals

17. Locate the wiper seal at the bottom of the control tower. This seal is difficult to remove and may require destruction. Use a pick or small tool, being careful not to nick the control tower’s metal casing, as damage can cause leaks.

Important: The wiper seal’s groove faces upward (toward the top of the tower). Install the new seal carefully with an appropriately sized socket, ensuring it is seated evenly.

18. On the passenger side of the control tower, replace the large o-ring in the groove with a new one from the kit.

19. Replace the smaller o-ring on the shuttle (originally from the shuttle’s end, near the white spacer) with a new one from the kit.

Step 9: Replace Steering Shaft and Shuttle Seals

20. Locate the shuttle on the steering shaft. Remove it by first removing two snap rings, washers, and the seal mechanism using needle-nose pliers and a pick.
21. Replace the hard white rubber ring and rubber o-ring on the seal mechanism with new ones from the kit (the new plastic ring is blue).
22. Replace the two rubber o-rings under the washers with new ones from the kit.

23. Inside the shuttle, remove the wiper seal and hard plastic spacer. Use an appropriately sized socket to tap out the seal.
24. Install the new spacer and wiper seal, ensuring the seal’s groove faces outward (toward the passenger side of the vehicle).

25. On the outside of the shuttle, replace the hard plastic ring and rubber o-ring with new ones from the kit. The o-ring goes on the outer side of the plastic ring.

Step 10: Replace Steering Sleeve Seals

26. Inside the bronze steering sleeve, locate the wiper seal, plastic spacer, and plastic guide ring.
27. Use a small pick and needle-nose pliers to remove the plastic guide ring carefully.

28. Select a socket slightly smaller than the sleeve’s inner diameter to tap out the wiper seal and spacer from the opposite end. The seal’s groove should face the control tower (driver’s side).

29. Install the new plastic guide ring, spacer, and wiper seal using an appropriately sized socket, ensuring the seal is tapped in evenly and oriented correctly.

Step 11: Reassemble the Steering Rack

30. Reassemble all components in reverse order, ensuring all seals are correctly oriented and seated.
31. Reinstall the hard lines with new o-rings, tightening the bolts to 20 Nm (15 ft-lbs) using a 6mm (1/4 inch) Allen wrench.
32. Screw the locking collar back onto the rack to secure the two halves, using a punch and hammer if needed.

Step 12: Reinstall the Steering Rack

33. Follow the Power Steering Rack Removal procedure in reverse to reinstall the steering rack in the vehicle.
34. Refill the power steering fluid reservoir with the correct fluid (refer to your Porsche 944 owner’s manual for specifications).

Post Procedure Checklist

• Check for fluid leaks at all connections, especially around the hard lines and control tower.
• Verify smooth steering operation by turning the steering wheel lock-to-lock with the vehicle stationary.
• Check power steering fluid level after a short test drive of 5 miles (8 km) and top off if necessary.
• Ensure no unusual noises (e.g., whining or grinding) from the power steering system during operation.

Sources

• Clark’s Garage
• Pelican Parts
• Porsche 944 Workshop Manuals
• YouTube