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Diagnosing steering rack leak (940)

Fa182

Stage 1
Joined
Apr 4, 2016
Location
Austria
Just after I redid all the seals at the front of the engine and timing belt and water pump, my steering rack started to leak.
It leaks quite a bit now all of sudden, perfect timing.
It drips somewhere from around where the hoses go into the rack with the banjo bolts, or maybe it's one of the two hard lines on the rack itself, since they are around the same area on the rack.

Question now is, how do I tackle this where the leak comes from?
I don't have a lift and and have to do everything from the bottom with the car jacked up, so space below is limited and the rack itself is pretty obstructed visually.
I've read up a lot on how to actually dismount it so I know what to do, but will I be able to unmount the rack while laying on my back?
Or is that even necessary to undo the whole thing to diagnose?

I did make an order already from Skandix for new aluminium washers for the banjo bolts, sealing rings for the hard lines, rack mount and crossmember plate bolts already, just so I have them on hand.

Apologies for these pretty basic questions, but I just want to know what I'm getting myself into.
I appreciate any hints.
Thanks.
 
I have never seen a rack leak at the banjo fittings if someone hasn't already been working on the rack. Highly unlikely that is the problem. removing the rack is simple if you end up needing to do that. Everything is easily accessible from underneath the car just sitting on jackstands. There are only two bolts that go horizontally through the cross member that hold the rack in place. The steering yolk/u-joint assembly, outer tie rods and 2 hydraulic lines and the plate that completes the cross member are all that have to be disconnected/removed. It should take less than an hour to remove the rack, including putting the car up in the air.
 
Thank you.
On one hand it doesn't sound good that the banjo bolts are not a common source of a leak and would be an easy fix, but at least it's reassuring the rack should come out easily.
I don't think I have much choice if it's not obviously the banjo bolts.
 
Thank you.
On one hand it doesn't sound good that the banjo bolts are not a common source of a leak and would be an easy fix, but at least it's reassuring the rack should come out easily.
I don't think I have much choice if it's not obviously the banjo bolts.
Never say never. I'm not ruling out the banjo bolts. In 300+ Volvos I have never seen a leak at a banjo bolt fitting. If you have self serve car washes where you are remove the splash pan and take it to the wash and clean it. Drive it home and immediately inspect it for the location of the leak.
 
I am also chasing a leak on the CAM rack of my 1992 245. Mine is a rusty pinhole in a hard line on the rack. I would start by blasting everything as good as possible with brake cleaner and then looking for oil. You may not have to remove the rack? Good luck! hiperfauto was good enough to provide me with part#'s for the two steel lines that are on the rack.

Eurobikenut
 
Never say never. I'm not ruling out the banjo bolts. In 300+ Volvos I have never seen a leak at a banjo bolt fitting. If you have self serve car washes where you are remove the splash pan and take it to the wash and clean it. Drive it home and immediately inspect it for the location of the leak.
Great idea, will absolutely do that.

I am also chasing a leak on the CAM rack of my 1992 245. Mine is a rusty pinhole in a hard line on the rack. I would start by blasting everything as good as possible with brake cleaner and then looking for oil. You may not have to remove the rack? Good luck! hiperfauto was good enough to provide me with part#'s for the two steel lines that are on the rack.

Eurobikenut
I saw your thread, but didn't want to hijack it. My parts catalogue has come in handy many times for ordering the right stuff I need (y)
Unfortunately one of the two hard lines for my TRW rack is NLA, so I hope it's not the culprit.
 
Nasty. That's why I said never say never. I'm lucky to be in a region where corrosive de-icing chemicals were never used until recently. What is also interesting is the sealing washers on your rack were aluminum. I have never seen an aluminum sealing ring used on a 2/7/9 series rack out of the Volvo factory. They have always been copper. I'm glad it was that simple.
 
I don't know what exactly is used, but they put plenty of salt on our roads in winter and the bottom banjo bolt is pretty exposed.

The parts catalogue says they switched to aluminium rings from certain chassis number onwards for both 940 and 960's, for reasons I don't know. The numbers are quite high, so I don't think the switch was made before they were discontinued in the US.
 
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