Mid last year I had the steering rack in my 940 rebuilt due to wear and a small leak. Last weekend as I was driving into a car park I heard the power steering pump groaning loudly. I checked the reservoir to find it almost empty. Looking under the car I found there was oil leaking off both sides of the steering rack.
I took the car back to the shop on Wednesday. This morning they phoned me and said the rack is rooted and beyond repair. Somehow water had gotten into the rack and rusted the main shaft. I took these photos while I was there.
Question is how did water get in there? The only water the car has been near in the last few months is a couple of washes (hand washed using a hose - not a pressure blaster) and some very heavy rain in early December. I have NEVER driven it through water. They said the seal at the top where the shaft enters was still good. Both steering boots were full of oily water but the boots were sealed up. Assuming it's the original rack it lasted 26 years before needing a rebuild. But 5 months after a rebuild it's stuffed.
Fortunately I had a spare rack from a 940 I stripped a few years ago. I took that with me and they're going to check it over and see if it can be rebuilt. If not, I'm up for a replacement. I phoned the Volvo dealer just for a laugh but they don't supply parts for 940s anymore. So a used rack or a rebuilt rack may be my only options.