rack rebuilding or replacing?

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Rob M
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Re: rack rebuilding or replacing?

Post by Rob M »

Well got it all apart, took around 30 pictures of disassembly I was not sure how many can be posted on here, I was amazed at easy it all comes apart. It appears that not all of the seals in the kit will be used and once cleaned up all the bearing looked great,clean up and paint time.
Rob
88 XR4Ti Stock, Daily Driver
88 XR4Ti Lightly Modified.
James Wieler
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Re: rack rebuilding or replacing?

Post by James Wieler »

Hi Rob,
Please post as many pics as you can.
thanks
James
Cossy sway bar, Powerflex, Dynalites, Focus SVT rotors,Koni yellow sleeve over 8"x300lb/in springs,Scorch bumper cover, 17x7.5x40mm Binno wheels, 225/45-17 Kumho 712 tires
Rob M
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Re: rack rebuilding or replacing?

Post by Rob M »

Starting out

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Lines did not want to come out

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Little o rings on lines

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Removing cover

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Getting as much oil as I can out of the system

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Scribing lines on yoke and body

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Removing yoke

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Cover lid

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Removing nut from rotary valve

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Removing retaining rings upper and lower

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Removal of rotary valve

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To tired will do the rest tomorrow
Rob
88 XR4Ti Stock, Daily Driver
88 XR4Ti Lightly Modified.
hEaT
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Re: rack rebuilding or replacing?

Post by hEaT »

Cool!! Thanks for sharing.


Mods, any interest in getting a FAQ/Picture Repository on this? I have pics of the early rack being yanked apart, but it's different enough where this would be needed for someone working on a later rack.
James Wieler
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Re: rack rebuilding or replacing?

Post by James Wieler »

Nice, very helpful and I'm looking forward to more. How to the bearings feel? Was there any dead center looseness in your rack?
cheers
James
Cossy sway bar, Powerflex, Dynalites, Focus SVT rotors,Koni yellow sleeve over 8"x300lb/in springs,Scorch bumper cover, 17x7.5x40mm Binno wheels, 225/45-17 Kumho 712 tires
Rob M
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Re: rack rebuilding or replacing?

Post by Rob M »

From where we left off

Removing the snap ring

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Pulling out the Rack and piston rod guide. It took a few tries of good hard yanking to pull it out

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Removing Shaft Seal and Bearing

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Removing Seal. See the seal way down in the housing

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Remove rod guide from rack

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Other shaft bearings you can just see the seal on the other side

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piston rod guide, seal and washer

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General Picture of everything Note Don't pay attention to the o rings a couple of them aer in the wrong place

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Left over o rings I did find a place for the seal and the smallest 4 o rings

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James Wieler wrote:Nice, very helpful and I'm looking forward to more. How to the bearings feel? Was there any dead center looseness in your rack?
cheers
James
Bearing all great but i did find the drivers side housing does not have a seal so if the bellow is missing or torn dirt sand rock you name it can get the grease and shaft gears and make it (for lack of better words) feel weird. Steering over all was great.
Rob
88 XR4Ti Stock, Daily Driver
88 XR4Ti Lightly Modified.
James Wieler
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Re: rack rebuilding or replacing?

Post by James Wieler »

More nice pics and great description.
Can you clean the rust off of the piston rod guide with emory cloth or is it an issue?
Cossy sway bar, Powerflex, Dynalites, Focus SVT rotors,Koni yellow sleeve over 8"x300lb/in springs,Scorch bumper cover, 17x7.5x40mm Binno wheels, 225/45-17 Kumho 712 tires
MercMike
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Re: rack rebuilding or replacing?

Post by MercMike »

Super Post !
'85 XR
Rob M
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Re: rack rebuilding or replacing?

Post by Rob M »

James Wieler wrote:More nice pics and great description.
Can you clean the rust off of the piston rod guide with emory cloth or is it an issue?
I think I am going to use a 320 grain emery cloth to clean up a few of the rusty places, I also blasted the aluminum housing with walnut shells to remove all the years of corrosion build up turned out pretty nice.
Rob
88 XR4Ti Stock, Daily Driver
88 XR4Ti Lightly Modified.
James Wieler
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Re: rack rebuilding or replacing?

Post by James Wieler »

sounds like you are ready for re-assembly, can't wait for more pics of that
Cossy sway bar, Powerflex, Dynalites, Focus SVT rotors,Koni yellow sleeve over 8"x300lb/in springs,Scorch bumper cover, 17x7.5x40mm Binno wheels, 225/45-17 Kumho 712 tires
James Wieler
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Re: rack rebuilding or replacing?

Post by James Wieler »

looks like you had an instruction manual, where did you get it from?
Cossy sway bar, Powerflex, Dynalites, Focus SVT rotors,Koni yellow sleeve over 8"x300lb/in springs,Scorch bumper cover, 17x7.5x40mm Binno wheels, 225/45-17 Kumho 712 tires
Rob M
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Joined: Sun Apr 29, 2012 11:22 pm
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Re: rack rebuilding or replacing?

Post by Rob M »

James Wieler wrote:looks like you had an instruction manual, where did you get it from?
I searched the web for a few days and happened to come across this web site http://forum.bmwland.ru/index.php?act=a ... t&id=26966 it has all the instructions for our zf rack plus 3 others. I printed it out punched holes in the paper and put it in a 3 ring binder. I printed it because going back and forth between the pages takes to long on the computer.
Rob
88 XR4Ti Stock, Daily Driver
88 XR4Ti Lightly Modified.
James Wieler
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Posts: 472
Joined: Sat Jun 19, 2010 8:42 am

Re: rack rebuilding or replacing?

Post by James Wieler »

which version do we have?
Cossy sway bar, Powerflex, Dynalites, Focus SVT rotors,Koni yellow sleeve over 8"x300lb/in springs,Scorch bumper cover, 17x7.5x40mm Binno wheels, 225/45-17 Kumho 712 tires
Rob M
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Posts: 16
Joined: Sun Apr 29, 2012 11:22 pm
Location: Ft. Myers Florida

Re: rack rebuilding or replacing?

Post by Rob M »

James Wieler wrote:which version do we have?
Our rack type is 7831 955 111
Rob
88 XR4Ti Stock, Daily Driver
88 XR4Ti Lightly Modified.
James Wieler
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Posts: 472
Joined: Sat Jun 19, 2010 8:42 am

Re: rack rebuilding or replacing?

Post by James Wieler »

I took my rack out this evening, I think I'm screwed as there is some major pitting on the rack gears. The rack worked great (except for the leaking).
What do people think?
thanks
James
Image
Cossy sway bar, Powerflex, Dynalites, Focus SVT rotors,Koni yellow sleeve over 8"x300lb/in springs,Scorch bumper cover, 17x7.5x40mm Binno wheels, 225/45-17 Kumho 712 tires
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