ZF steering rack rebuild

I am working on rebuilding a zf steering rack out of a '95 BMW m3.  The adjuster screw on the bottom of the rack is seized preventing me from being able to replace the o ring or get good access to the back of the inner rack seal to drive it out.

I am waiting on an extractor the correct size for the bolt head, I am hoping that & some heat will get it moving.  As many Porsche & BMW's use similar racks I was wondering if anyone had any experience or advice on the rebuild or getting the adjuster screw out without destroying it or the steering rack.

I was just about to watch this, maybe it comes in handy:

that is very similar to the green tag rack I am working with. His rack adjuster screw came out for him though he did say the fitment of the 17mm was loose.  When I disassembled mine removing the lines helped get behind the cerclip he had issues with.

All in all a good video but he did not go into detail on the spots that are holding me up, thank you for posting though, it will probably be helpful again on reassembly.

I was able to get the adjuster screw out, unfortunately the screw itself did not fair well.

I will have to try to get one out of a car at LKQ without destroying it unless someone has any other ideas.

Any updates on this. 

My steering rack is leaking out of a side seal on my e46 M3 and I am wondering whether its best to give it a shot at rebuilding it myself. 

In reply to Slippery :

USUALLY if one of the side seals fail, it is either because debris got in behind the boot and scored the bore, or the rack can move radially in the housing because it is worn out. Not sure if ZF racks have replaceable bushings or if it is replace as assembly.

In reply to Pete. (l33t FS) :

That's my fear, that the metal is excessively worn and it will fail again once the seals are replaced. 

I can get a rebuilt one with inner tie rods/boots for $1k. Might need to bite the bullet. 

Ooooooooof.

Are there any specialists who might have a used one?  The rack for my S60R is only available from Volvo, $1400 or somesuch, but a company in PA that specializes in them has a few good used on the shelf for under $300.

It's a bit involved to replace, though, which is why I've just been putting a liter of CHF11S in it every month or so.  I'm waiting to find a good used torque converter for it because I want to tow with it but not with a 4000 rpm converter, and new converters are also four figure items.  The front subframe has to come out for both operations, so I like to combine when I can.

I still need to source the adjuster screw.  So far the used ones I've found in the junkyard have not budged when trying to remove.  The newer zf electric racks use a very similar screw that I was able to get out but it is slightly larger.

Rack doctor used to be a good source for rebuilt BMW racks, I have one of their gold label racks in my e36 m3.  Recent reviews of their response time have not been good though.

In reply to Caperix :

I'd advise against using rackdoctor ... luckily you already know. 

In reply to Pete. (l33t FS) :

$1k is a rebuilt one from FCP Euro. Lifetime warranty at least. 

Dealer wants $1700 including discount, lol. 

The kit I found from Edelman I purchased from summit for less than $50.  No special tools required, just a selection of sockets & extensions to drive the seals out & in.  

In reply to Caperix :

How did you find what part number kit you needed for your rack? Is there a catalog I am not finding online? 

I just cant find any that will fit mine. 

Rockauto & summit racing sell them & have listings for some.  I ran into the issue with mine being a 95 that had a 1 year only rack that was not listed any place.  I found a post on bimmerforums that someone had used a 9175 kit & the pinion seal from a 9046 kit.  I ordered them both, the 9175 had all the seals I needed for mine.  The pinion seal size, the rack adjuster & the vent lines look to be the main differences in this generation of zf racks.

Is there a catalog for cross referencing?

I only need a rack because the pinion seal is leaking.  I am perfectly willing to try to repair it myself, if I could find the parts.  Might even be able to do it with the rack in chassis instead of removing the subframe. 

The rear motor mount bolts to the rack, not the subframe.  Not much room to do much else in a car the size of a Civic when the HVAC case, the rack, the pumpkin-sized turbo, the exhaust, and the AWD transfer box all want the same space.  This is why rack R&R sucks more than $40 a month in power steering fluid.

In reply to Pete. (l33t FS) :

There has to be a catalog somewhere, I just have not found it yet. If I do I will post the link. 

In the meantime I picked a used rack off of Ebay, so I can dissect mine and see what I find and how hard it is to disassemble. It was cheaper than the core charge for a rebuilt one and they offered a  60 day return.