Steering rack, driver's side rear wheel bearing, thermostat housing and clutch all bit the dust these past two weeks...with 142K miles on the odometer.

Must warn others

 

Oooooh, sounds like a fun weekend!

 

Whew.... I'm safe by 100K miles still....

Sorry for your troubles, though. Good luck with repairs.

 

Wow!

Wait...you've already put 142K on a 2005???!!!

 

Unfortunately Michael those are all pretty common failures on the R53. Though the steering rack failure is usually reserved for the '02, you have put yours through lots of track day paces. Are you sure it wasn't just the pump crapping out?

I'm impressed you got 142k out of your clutch! That's alot for a stocker.

 

Well I have a philosophy about brakes and clutches...brakes are easier to replace...so I use the brakes instead of downshifting whenever possible. I don't observe this philosphy on the track

The cooling problem I PM'd you about Ryan will hopefully be cured by a new thermostate and housing.

The rack is the only part I cannot really diagnose: when the front end is off the ground, there is a metallic grinding/clunking coming from the union of the rack and pinion gear area as I pull on a tire at 9 and 3 O:clock - to full lock in both directions. The sensation while driving is clucnkiness when traversing bumps and very odd motions when traversing smooth undulations. and these are almost only noticable when one tire receives an input...the front end feels very solid when crossing expansion joints...RR tracks send the front end into awild quiver. I am assuming that the pump is working since I the powersteering feels fine.

...perhaps the Powerflex bushings transfer some impact energy into the rack...these have been on the car for quite a while.

This is a company car...I was just told this morning to park it for the winter and drive one of the A4 V6s hanging around...a nice car, but not very involving from a driving perspective.

...and a wee bit of a pig at about 18 mpg

 

did you ever change power steering fluid?

have you ever changed tie rods?

 

Fluid, no. But the last time I removed the sub-frame, the plug I installed in the reservoir fell out and a lot of fluid with it. So I re-filled it...

tie rods...outer tie rods twice on each side...inners are original. I replaced all of the ball joints, LCA bushings and swaybar bushings last May when I installed the JCW kit. At that time I performed a quick, but perhaps incomplete check of the inner tie rods and rack; I grabbed each tie rod and pulled a few times to opposite lock and all seemed to move smoothly and in sinc. I then used my fingers to spin the shaft stud on the rack that feeds into the steering shaft U joint...it also felt solid and as well, moved the tie rods in since. Now, fingers are great when we need to pick up tingly little messages, but not so great at dicserning, or forcing big movements. I dunno...

Kieth suggested a couple of additional tests to help isolate the rack from the steering shaft...I simply need another set of hands and eyes before I plunk down $1,000 for a rack...when perhaps the steering shaft is the problem.

Any thoughts are of course welcome! I have been feeling a front end problem for close to two years and every time I change bushings, ball joints etc, the car feels great for about two weeks.

A quick question, when the steering shaft is removed from the stud on the rack, it will fall a little? Meaning, and to might utter surprise, there isn't a bearing of some sort that holds the shaft as it passes thru the fire wall? Won't I feel dumb...if there is, was one, where'd it go

 

Hmm I'm interested in hearing what you find about your steering problem. Aside from my wheel bearings needing replacement I think something is up with my steering. I get a click sort of feel when turning left or right and the wheels are straight.

 

...clicking while in motion or standing still? Sounds like CV joint(s).

...I am seriously hoping I don't have a transaxle problem...I'm not so sure its the rack...lots of movement from other parts and some odd highway vibration goes completely away when I coast - out of gear...who knows

 

Steering racks are pretty old technology. Many local, good mechanics should be able to analyze and advise. There are places that rebuild racks at a fair price. The RX7 guys use this place: http://www.mavalgear.com/ Cost for us is under $300

 

I'll disconnect the steering shaft and tie rods and play for a bit...hopefully that will tell me something.

 

PM Sent so I don't ruin your thread.