Steering rack removal and refurbish part I

This was never really in the plan. Yes it did have a small fluid leak wetting the inside of the gaiters, and some discoloration of the steering fluid. But nothing serious. However the engine mount project required the rack to be dropped (the ball joints stayed in place.) So it seemed an opportune time to remove it and send for refurbishment.

I used in Steering Specialists Wakefield  because they had done a good job with a picanto caliper, and they were really easy to communicate with. No regrets. Collection and return of the rack was so easy. I strapped it to a plank of wood and put it into a cardboard box. They removed all extra bits liek ball joints and returned them loose. ACS in Walsall have been used by other Iveco people and get good reports.

I found it very difficult t install. I tried repeatedly with the steel ppes attached because they are so hard to reach once installed. But eventually i gave in and put the rack in first and used a short spaner to conect the pipes.

New hydraulic hoses from our local farmers store. The standard size available for the small hose was a really tight fit. I used my hot air gun to soften it. It wold not have been possible otherwise.

Wheel alignment afterwards was not trivial. I've been told I could do it myself - but I've always thought of it as a specialist task.

1) Garage says the ball joints on the rack ends were loose, so I replaced them although I could not feel any play.

2) local wheel alignment people charge £40 but don't have tools for my wheels/tyres (The hub cap things protruded a lot)

3) The main HGV dealer charged a fortune, but later apologised and accepted no payment.

The result: feels great.I'd never guessed the steering would feel so much better.

Cost was £220 inclusive

Other parts I needed were:

Steering fluid Dexron II D that is red from halfords

Filter 1902137 £5.95 genuine Iveco part from eBay

Rubber bush SILENTBLOCK STEERING GEAR LEMA LE2516.00 eBay £12.25 from Poland

Replacement bolts, M10 fine  (The thread was rusty on the old ones, I even re-tapped the housing)

Ball joints 8584193 (I had some spare ones - that was very lucky)

There is a part II to the story one year later