S60 Steering: Deafening rack woes after power steering work

[andbark]

Hi all,

I started a thread last year where I incurred a terrible groaning sound from either end of the steering rack following the replacement of a leaking high pressure power steering hose. (Link to the threadhttp://www.volvoforums.org.uk/showthread.php?t=234850)

The sound was only evident at very low speeds, such as when parallel parking. This noise has never gone away and I’m at the point of needing to spend money on the car elsewhere to keep it going, but this unresolved problem is putting me off.

To summarise:

• The leaking high pressure power steering hose was replaced with a good second hand hose. It fits perfectly, and I’ve confirmed that it is clear of blockages having blown through it and put compressed air through it before installation. Yet the groaning started immediately after the part was fitted.
• I flushed the system compressively with the correct green fluid.
• I changed some of the aging engine mounts (top, brace and front lower) in case the engine was putting pressure on the rack.
• I have confirmed that there are no leaks in the system nor any air ingress.

In addition:

• The power steering works perfectly apart from the noise. The car has clocked up another 10k or so and has been MOTed without issue.
• It does not suffer the ‘pulsing/pumping’ feel that is described as the symptom of a failing steering rack elsewhere in the forum.
• The noise comes from the extreme ends of the steering rack around the track rod end area.

I’m not averse to tackling any job to repair this, but would hate to thrown money and time at; for example, a new power steering hose or a replacement steering rack only to find that there’s no change.

Any advice?

Andrew
2002 S60 D5 - 289k

[4candles]

Have you checked inside the steering gaitors, do you have some fluid in here?

I had a noise on my XC70 and there was a loose hose at the pump, tightening this cured it momenterally but the noise came back,,,i then changed the PS tank to the later type and hey presto all noise is a thing of the past now and although i've sold it i still maintain it and new owner (mate) is enjoying it thoroughly with no issues. It is a low mileage example (65k) but i see yours is a smidgeon over that figure so my thoughts are you may well need a replacement rack.

If you've not done so i'd remove the gaitors (bellows) from the rack ends and see what you have, but it sounds like worn seals.