Technical Need your opinion please, new steering rack makes noise.

[panda81]

I replaced the steering rack on my wifes 169 1.2 2008 fiat. The old rack had a loud clunking noise with wheels turned to full. Inner and outer joints were fine. First video is of old rack out. You should be able to hear a light clunk sound while I turn it on bench with vise grip.

The next to videos is the new rack fitted. Something MUST be wrong here....!!! I should also mention I replaced everything while at it. Wishbones, wheel bearings, tie rods, the steering knuckles that connnect to the sway bar (sorrry dont know what you call them in UK, in Danish we call them "meat bones"). Also checked the knuckle/pinion from column to rack no play. Everything is tightened up as should be. Car was aligned at shop with no problem.

Is this a faulty replacement rack? TRW remanuctured. Is it okay to have this play. When driving the sound is not heard.

 

[bugsymike]

I replaced the steering rack on my wifes 169 1.2 2008 fiat. The old rack had a loud clunking noise with wheels turned to full. Inner and outer joints were fine. First video is of old rack out. You should be able to hear a light clunk sound while I turn it on bench with vise grip.

The next to videos is the new rack fitted. Something MUST be wrong here....!!! I should also mention I replaced everything while at it. Wishbones, wheel bearings, tie rods, the steering knuckles that connnect to the sway bar (sorrry dont know what you call them in UK, in Danish we call them "meat bones"). Also checked the knuckle/pinion from column to rack no play. Everything is tightened up as should be. Car was aligned at shop with no problem.

Is this a faulty replacement rack? TRW remanuctured. Is it okay to have this play. When driving the sound is not heard.

If it is a manual steering rack, then it isn't right and I would have failed it as an MOT Tester when foreman of garage in the past..
Power steering racks I have found sometimes have a slight movement when engine off, but it goes away with engine running, although this for hydraulic power steering and not electric type.
Usually there are two main places that wear, the first is the pinion against the rack gears, which in a manual steering rack can often be corrected by removing a shim behind the plate that is spring loaded to push pinion into mesh with the rack. Note if too many shims removed rack locks up!
The other area that can knock is usually the passenger side of the rack as it is the longest with only the bearing/bush at the inside of rack at that end to support it. When that makes a noise, if on a ramp and someone pulls down on the steering arm the noise will stop as a test.
Yo can also get play in the inner steering rack ball joints that can be seen when rack boots are removed. These can be bought separately to the rack.
Track rod ends are the steering joints on the outer ends of the steering rack that can be adjusted to align steering.
I think your "meat bones" are the antiroll bar/sway bar "drop links".
Although you may not hear the knock when driving, how precise is the steering?

 

[koalar]

Test 1

If you jack up one side

Then try

Jack up the other side

Then try

Is the noise the same

They aren't totally silent, but it sounds excessive to me

Assuming both sides are the same

Test 2

Disconnect the tie rod ends

Is the noise still present

 

[panda81]

It is electric steering so without fluid. I jacked up the car and the noise is definately from the rack itself, could be tie rod left hand side (came with the replacement rack). I dont want to replace these as I would need to pay for alignment again without assurance that it will solve the problem. I just contacted Misterauto where the rack was bought hope they will send a replacement. Also I ruled out the pinion on the steering shaft as the noise is the same without steering wheel attached to the rack.

 

[bugsymike]

It is electric steering so without fluid. I jacked up the car and the noise is definately from the rack itself, could be tie rod left hand side (came with the replacement rack). I dont want to replace these as I would need to pay for alignment again without assurance that it will solve the problem. I just contacted Misterauto where the rack was bought hope they will send a replacement. Also I ruled out the pinion on the steering shaft as the noise is the same without steering wheel attached to the rack.

Originally you mentioned the recon rack was by TRW which is a fairly well known make, so if that is the case I am surprised that they would supply faulty parts.

 

[panda81]

It was bought actually as triscan brand but it says trw on the rack itself

 

[bugsymike]

It was bought actually as triscan brand but it says trw on the rack itself

Oh! So just some rebuild company, rather than a TRW branded product.

 

[koalar]

TRW are often remanufactured

Even though the advert doesn't say

Here an answer from a question, although it for a TRW banded rack for a honda

Dear A. , Thank you for your question!
Steering Gear TRW Article №: JRP934 is reconditioned item with 2 years warranty.
Best Regards, Online car parts Team

Triscan is also a rebuild company and are known to be inconsistent , usually seals failing on hydraulic units, so doesn't apply here

My guess is the preload is set incorrectly, of course the could be wrong and is pure speculation