Have fun, it's not too bad a job to be honest, once you've got the rack on the bench it comes apart pretty easy. If there's any rust on the rack, imo best bet would be to get another rack that's rust free and rebuild that instead. If there's rust/missing chrome plating, it will be probably near the ends, like the area under the tie rod boots.

Also be careful with the input shaft, it has an assembly around it that is what does the work of sending pressure to the correct side of the rack, it's got a bunch of o-rings I forget if the kit includes those or not so just avoid breaking anything before checking you've got the new part.

The pinion preload screw has some threads staked I think, I ended up just ignoring it and unscrewing the cover and just applying a bit more force to get it past the staked threads.

If you get a USA kit will car want to drive on other side of road then?????

Thanks Jameinc, appreciate the advice, I'm sure I've had to do worse jobs! I agree if there;s any pitting or rust its toast! finger's crossed.

I hope it doesn't pull to the right too much Ex850R!

    Stoonly

    Haha

    Is it feasible to have a shaft chromed again ?

    I feel it wouldn’t be cheap knowing engineering places but they may be able to make a new one too.

    I bet Mark at Berrys knows the options.

      Active Steering in Sydney are experts with Volvo rack professional rebuilds and use genuine UK parts.

      Can’t recommend them highly enough.
      I always send my known rack for servicing, but hear they have a swap service.
      General figure around $650 to these days, maybe less. They pressure test them too.
      Im not sure if I recommend people doing this work themselves.
      To finish its best to fit new tie rod ends, then arrange a wheel alignment and it will all be like new again.

      Thanks Anthony, We've got three 240's so knowing how to refurbish a rack will be useful I'm sure! if it gives me grief I'll know next time to get it done somewhere, I'm up on the sunny coast so sending it to Sydney is a pain.

      I'll let you all know how it went.

      7 months later

      VolvoHordz sorry to revive a dead forum; could you please send me the greenbook for cam gear steering rack rebuilding?

        I have tp30664, which doesn't appear to be in the archive. I will endeavour scan it in tomorrow and share it.

        Need to re-familiarise myself with it anyway. The rack I rebuilt leaks from the drivers side end of the rack. I can only suggest being particularly cautious when putting the shaft through the seal.

          tp30664-760-power-steering-grear-cam-gear.pdf
          16MB

          Enjoy. Whilst it says 760 and is based on a LHD car, from what I recall it is the same as a 240 rack in terms of rebuilding it. Note that the rebuild kits typically not come with everything, in particular the teflon rings. Don't get too carried away stripping every last thing off until you have confirmed you have a replacement.

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