Rack and Pinion Boots

Replace the steering rack and pinion boots to prevent contamination and leaks in the hydraulic steering system.

Warnings

Tools required

Parts

• Steering rack boot kit (includes boots and clamps) × 1 — A2214600396 or equivalent
• Power steering O-ring set × 1 — Use OEM specification
• Cotter pins for tie rod ends × 2 — 2mm x 20mm
• Degreaser/brake cleaner × 1 — N/A

Fluids

• Pentosin CHF 11S — 1 qt

Preparation

1. Park vehicle on level surface and set parking brake
2. Turn steering wheel to center position and lock with steering wheel lock or tape to prevent rotation
3. Raise front of vehicle and secure on jack stands at manufacturer-specified lift points
4. Remove both front wheels
5. Place fluid catch pan under steering rack area
6. Take photos of routing and connections for reference during reassembly

Procedure

1. 1

   Remove front underbody panels
   Remove the engine splash guard and steering rack access panels using appropriate sockets. These panels are secured with multiple fasteners. Keep fasteners organized for reinstallation.
2. 2

   Disconnect tie rod ends
   Remove the cotter pins from both tie rod end castle nuts using needle nose pliers. Loosen but do not remove the castle nuts. Use tie rod end separator to break the taper connection between the tie rod end and steering knuckle. Once separated, fully remove the castle nuts. Support the tie rod end as it releases from the knuckle to prevent damage.
   ⚠Tie rod ends may release suddenly when taper breaks. Keep hands clear of pinch points.
   Torque spec

   Tie Rod End Castle Nut55 Nm (41 lb-ft)
3. 3

   Disconnect power steering lines from rack
   Using a flare nut wrench, carefully loosen the power steering pressure and return line fittings at the steering rack. Be prepared for fluid spillage. Cap or plug the open lines and rack ports immediately to prevent contamination. Discard old O-rings from the fittings.
   ⚠Power steering fluid will drain from lines. Position catch pan to collect fluid.
   Torque spec

   Power Steering Line Fittings30 Nm (22 lb-ft)
4. 4

   Remove inner tie rod lock nuts
   Locate the tie rod lock nuts on the inner tie rod ends where they thread into the steering rack. Use appropriate wrenches to loosen and remove these nuts. Mark the position of the tie rod relative to the rack threads with paint or marker to aid in maintaining approximate toe alignment during reassembly.
   Torque spec

   Tie Rod Nut73 Nm (54 lb-ft)
5. 5

   Remove old rack boots
   Using pliers or boot clamp tool, release the clamps securing both ends of each rack boot. The boots have one clamp at the rack housing and one at the inner tie rod. Slide the old boots off the rack assembly. Inspect the rack surface for damage or excessive wear.
   ℹ️If boots are severely damaged, inspect rack shaft for scoring or damage that may require full rack replacement.
6. 6

   Clean rack shaft and housing
   Thoroughly clean the exposed rack shaft, inner tie rod threads, and boot seating surfaces using brake cleaner and clean rags. Remove all old grease, dirt, and debris. Inspect the rack shaft for scoring, pitting, or corrosion. Light surface rust can be cleaned with fine steel wool, but deep pitting requires rack replacement.
7. 7

   Install new rack boots
   Apply a light coating of fresh Pentosin CHF 11S to the rack shaft. Slide the new boots onto the rack assembly, ensuring the smaller end seats properly in the groove on the rack housing and the larger end seats on the inner tie rod. Ensure boots are not twisted and sit flush in their mounting grooves.
8. 8

   Secure boot clamps
   Install new clamps at both ends of each boot using the steering rack boot clamp tool. Ensure clamps are positioned in the designated grooves and tightened securely. Clamps must be tight enough to seal but not so tight as to cut the boot material. Verify boots can flex freely without binding.
9. 9

   Reconnect inner tie rods
   Thread the inner tie rods back into the steering rack to the previously marked positions. Install and tighten the tie rod lock nuts. This maintains approximate toe setting, but professional alignment is still required.
   Torque spec

   Tie Rod Nut73 Nm (54 lb-ft)
10. 10

    Reconnect power steering lines
    Install new O-rings on the power steering line fittings, lubricating them lightly with Pentosin CHF 11S. Thread the pressure and return lines back onto the steering rack by hand first to avoid cross-threading. Tighten to specification using a torque wrench and flare nut wrench.
    ⚠Cross-threading these aluminum fittings will require expensive rack replacement. Start all threads by hand.
    Torque spec

    Power Steering Line Fittings30 Nm (22 lb-ft)
11. 11

    Reconnect tie rod ends to knuckles
    Clean the tie rod end tapers and steering knuckle bores with brake cleaner. Insert tie rod ends into steering knuckles and install castle nuts. Tighten castle nuts to specification. Align the castle nut slots with the tie rod end holes by tightening only (never loosen to align). Install new cotter pins and bend tabs to secure.
    ⚠If castle nut slots do not align with cotter pin hole at specified torque, tighten further to next alignment point. Never loosen to align.
    Torque spec

    Tie Rod End Castle Nut55 Nm (41 lb-ft)
12. 12

    Reinstall underbody panels and wheels
    Reinstall all underbody panels and splash guards removed earlier. Install both front wheels and hand-tighten lug nuts in a star pattern. Lower vehicle to ground and torque lug nuts to specification in a star pattern.
    Torque spec

    Wheel Lug Nuts183 Nm (135 lb-ft)
13. 13

    Refill and bleed power steering system
    Fill power steering reservoir to MAX mark with Pentosin CHF 11S. Start engine and turn steering wheel slowly from lock to lock 10-15 times while monitoring fluid level. Add fluid as needed. Check for leaks at all connections. Continue until no air bubbles appear in reservoir and fluid level stabilizes.
    ⚠Do not hold steering at full lock for more than 5 seconds as this can overheat the power steering pump.

Reassembly

1. Verify all power steering line connections are tight and leak-free
2. Ensure steering wheel is still centered and steering angle sensor was not disturbed
3. Check that all underbody panels are securely fastened
4. Verify all clamps are properly seated in boot grooves with no twisting

Verification

• Start engine and verify smooth power steering operation with no noise or binding
• Check for power steering fluid leaks at rack connections and boot clamps with engine running
• Turn steering wheel lock to lock and verify boots flex properly without tearing or detaching
• Verify power steering fluid level is at MAX mark after system has been operated
• Schedule front-end alignment immediately to restore proper toe settings
• Test drive at low speed in a safe area to confirm normal steering feel and response

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