Power Steering Rack Replacement – 2.5L NA

Overview

This procedure replaces the power steering rack on a Porsche 944 (8-valve engine configuration), covering pre-1985.5 (83-85.5) and 1985.5 onwards (86-88) variants. The power steering rack is critical for smooth and responsive steering, and replacing a worn or damaged rack restores proper vehicle control. This guide is designed for DIY enthusiasts with mechanical experience, ensuring safe and accurate installation. Always follow safety precautions, as improper installation can lead to loss of steering control.

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Tools Required

• Jack stands or ramps
• Floor jack
• Drop light
• Wheel blocks
• 19mm (3/4 inch) wheel wrench
• 19mm (3/4 inch) wrench
• 17mm (11/16 inch) wrench
• 10mm (3/8 inch) socket
• 12mm (1/2 inch) wrench
• 13mm (1/2 inch) wrench and socket
• 30mm (1-3/16 inch) wrench (Pre-85.5, some European models may require 32mm (1-1/4 inch) wrench)
• 6mm (1/4 inch) Allen wrench
• 10 inch (254mm) adjustable wrench
• 3-quart (2.8-liter) low-profile catch basin
• Small gear puller
• 8 inch (203mm) long 3/8 inch drive extension
• 12 inch (305mm) long 3/8 inch drive extension
• Flat blade screwdriver
• Cold chisel
• Flat-nosed chisel (drift)
• 3 inch (76mm) vise with soft jaws
• Short pry bar

Parts Required

• Power steering rack (933-347-011-24)
• Tie rod ends (944-347-033-23, 2 required)
• 1 quart (0.95 liters) Dexron II or III automatic transmission fluid
• Miscellaneous hardware (bolts, washers, etc.)
• Bronze crush washers (for pressure and return lines)
• Plastic tie wrap

Step-by-Step Procedure

Step 1: Prepare the Vehicle

1. Park the vehicle on a flat surface with at least 1 meter (3.3 feet) of clearance around it.
2. Engage the parking brake, open the driver’s side window, and block the rear wheels.
3. Disconnect the negative battery terminal using a 10mm (3/8 inch) wrench.
4. Loosen the front wheel lug nuts using a 19mm (3/4 inch) wheel wrench, but do not remove them yet.
5. Jack up each side of the vehicle at the designated jacking points and place jack stands under the frame rails, ensuring at least 18 inches (457mm) of ground clearance.
6. Remove the front wheels and set them aside.
7. Remove the undercover panel (belly pan) by removing seven 10mm (3/8 inch) bolts using a 3/8 inch drive ratchet and socket.
8. Place a 3-quart (2.8-liter) catch basin under the power steering pump.
9. Using a 19mm (3/4 inch) wrench, remove the pressure line from the pump and let the fluid drain into the basin.
10. Turn the steering wheel lock-to-lock several times to drain fluid from the steering gear, then allow it to drain completely.

Step 2: Remove the Front Sway Bar

11. On the passenger side, remove the two clamp bolts securing the sway bar to the frame anchor using a 13mm (1/2 inch) socket and a 13mm (1/2 inch) wrench.
12. On the driver’s side, remove the two bolts attaching the sway bar frame anchor to the frame using a 13mm (1/2 inch) socket with an 8 inch (203mm) long 3/8 inch drive extension.
13. Remove the nut attaching the sway bar to the control arm on each side using a 17mm (11/16 inch) wrench, then remove the sway bar.
14. Loosen the clamps on the alternator cool air intake tube using a flat blade screwdriver and remove the tube.

Step 3: Disconnect the Tie Rod Ends

15. On each side, loosen the locking nut on the tie rod end ball joint using a 19mm (3/4 inch) wrench until it is just above the stud’s end.
16. Use a small gear puller to disconnect the tie rod end from the steering knuckle. Alternatively, strike the steering knuckle with a hammer to pop the tie rod end loose, avoiding damage to the rubber boot.

– If your vehicle uses self-locking nuts (rounded top, no washer or cotter pin), replace them with standard nuts and locking washers, as they are not reusable.

Step 4: Disconnect the Steering Column Universal Joint

17. Turn the steering wheel to align the universal clamp bolt head with your access point from under the vehicle.
18. Place a 13mm (1/2 inch) wrench on the nut behind the steering column and use a 13mm (1/2 inch) socket with a 12 inch (305mm) long 3/8 inch drive extension to remove the clamp bolt.
19. Apply light pressure with a short pry bar or large screwdriver to loosen the clamp from the steering gear shaft. The clamp will fully detach when the rack is lowered.

Step 5: Remove the Steering Rack

20. Remove the return line from the steering gear housing using a 6mm (1/4 inch) Allen wrench.

For Pre-85.5 models:

– If the Allen head hollow bolt is seized, use channel locks to remove it. Consider replacing it with a hex head hollow bolt for easier reassembly.

For 85.5 Onwards models:

– Check if the bolt is a hex head or Allen head and proceed accordingly.

21. Remove the pressure line support clamp and the attached ground wire from the rack housing.
22. Remove the four rack mounting bolts using a 13mm (1/2 inch) wrench.
23. Slide the rack out of its mounting journals while slipping off the steering universal joint, lowering the rack assembly.
24. Remove the following from the old rack for the new rack: high pressure line support clamp with 10mm (3/8 inch) bolt, rack line rubber spacer, plastic compensating line with L-shaped fittings, and left and right side mounts.

Step 6: Remove the Tie Rods from the Old Rack

25. Label the left and right tie rod ends for reassembly.
26. Pull the boots away from the steering gear housing to expose the inner ball joints.
27. Extend the driver’s side of the rack fully to expose about 75mm (3 inches) of rack teeth.
28. Clamp the rack teeth tightly in a 3 inch (76mm) vise with soft jaws (e.g., aluminum angle pieces).
29. Use a cold chisel to remove the peened flange portion from the locking notch at each end of the rack.
30. Remove the tie rod assemblies using a 30mm (1-3/16 inch) wrench (or 32mm (1-1/4 inch) for some Pre-85.5 European models). Both ends are right-hand thread.

Step 7: Install Tie Rods on the New Rack

31. Secure the new rack in the vise as described in Step 6, ensuring no pressure is applied to the gear mechanism.
32. Screw in the labeled left and right tie rod assemblies to maintain approximate alignment.
33. Tighten each tie rod assembly to 70 Nm (52 ft-lbs) using a 30mm (1-3/16 inch) wrench (or 32mm (1-1/4 inch) for some Pre-85.5 European models).
34. Use a flat-nosed chisel (drift) to peen the inner ball joint flange into the locking notch. Do not use thread lock products.
35. Remove the rack from the vise and reinstall the boots on the steering gear housing.

Step 8: Prepare the New Rack for Installation

36. Slide the left and right side mounts into place on the new rack.
37. Install the rubber spacer under the rack line.
38. Attach the high pressure line using new bronze crush washers, tightening to 20 Nm (15 ft-lbs) with a 6mm (1/4 inch) Allen wrench.
39. Loosely attach the support clamp with a 10mm (3/8 inch) bolt.
40. Insert the L-shaped fittings on the compensating line and push them firmly into place on the rack housing.

Step 9: Install the New Rack

41. Center the rack by removing the threaded plastic plug from the view port on the underside of the steering gear housing and turning the steering shaft until the red dimple aligns with the view port.
42. Thread a 10x1x35mm bolt with a tapered end (or a ball bearing and standard bolt) into the view port to lock the rack in place.
43. Position the rack assembly on the passenger side and finger-tighten one mounting bolt, letting the driver’s side hang slightly.
44. Reach through the driver’s window and turn the steering wheel until it is straight (an assistant can hold it in place).
45. Align the universal clamp’s split with the center of the steering gear shaft’s flat side.
46. Push the rack assembly into position, sliding the universal clamp down the steering gear shaft.
47. Install and hand-tighten the upper driver’s side mounting bolt. If needed, lightly tap the clamp with a hammer until the shaft flat is not visible.
48. Install and tighten the clamp bolt, then finger-tighten the remaining two mounting bolts.
49. Tighten all four rack mounting bolts to 23 Nm (17 ft-lbs).
50. Install the high pressure line mounting clamp and ground wire.
51. Attach the high pressure line to the power steering pump with new bronze crush washers, tightening to 45 Nm (33 ft-lbs).
52. Attach the return line to the rack housing with new bronze crush washers, tightening to 20 Nm (15 ft-lbs).
53. Secure the high pressure and compensating lines to the rack with a plastic tie wrap at the rubber spacer’s location.
54. Remove the centering bolt (if used) and replace the view port plastic plug.
55. Connect the tie rods to the steering knuckles, tightening the locking nuts to 41 Nm (30 ft-lbs) while preventing the ball joint shaft from turning (use a gear puller or similar tool).
56. Install the fresh air tube and the driver’s side sway bar mounting bracket.
57. Install the sway bar by connecting the ends to the control arms first, tightening bolts to 24 Nm (18 ft-lbs).
58. Raise the sway bar with a jack until the mounting clamps align with the brackets, then install and tighten clamp bolts to 23 Nm (17 ft-lbs).

Step 10: Bleed the Power Steering System

59. Install the wheels and lower the vehicle from the jack stands.
60. Fill the power steering reservoir with Dexron II or III automatic transmission fluid.
61. Reconnect the battery and start the engine.
62. Wait a few minutes for the fluid to circulate.
63. Turn the steering wheel lock-to-lock slowly until no air bubbles appear in the reservoir and the fluid level stabilizes.
64. Check the fluid level with the engine off and running. If the level rises more than 10mm (0.4 inches), repeat the bleeding process.

Post Procedure Checklist

• Verify no fluid leaks at the pressure and return line connections.
• Ensure the steering wheel turns smoothly lock-to-lock without binding.
• Confirm the rack mounting bolts are tightened to 23 Nm (17 ft-lbs).
• Check that the tie rod end locking nuts are tightened to 41 Nm (30 ft-lbs).
• Verify the power steering fluid level is stable and free of air bubbles.
• Schedule a front-end alignment at a professional shop.

Sources

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