Steering rack and steering pump leak

[Razor61]

A few weeks ago I noticed a noise under hood when starting the car from cold and then it settled down after a few secs. Power steering pump type noise so checked the steering fluid level and it was low, topped it up and it has gone now. Did an oil change a few weeks ago and checked the passenger side steering rack boot, it was split with some greasy/oily residue round it. I noticed this residue quite a while ago, made a mental note to check it out but didn’t get round to it until a few weeks ago when doing the oil change.
Anyhow, ordered both steering rack boots and fixings from Amayama and fitted them this morning. Jacked up, wheels off, calipers off, tie rods off, locking nuts off to remove the steering boots. Drivers side was dry but passenger side is leaking, not gushing out by any means but it’s definitely leaking which explains the steering pump noise when the fluid got too low. It was on the ‘plan’ of work for today to check the power steering pump for leaks as well, there is fluid around the idle up valve and below on the sway bar and other pipes where is dropped down. Not really bad but it’s coming from somewhere. Wiped it all as best I can and will take the car for a run tomorrow and check to see if I can located the source of the leak. It’s not from the reservoir area, it’s different from the mk3.
Steering rack needs sorting and the leak around the pump.
As I see it I have a few options for the steering rack.
Buy a new one from Amayama - £1100 plus import duty etc. plus any pipe work needed.
Remove the existing one and have it refurbished/rebuilt or buy a used one and have it refurbished. There is a specialist near where I live that can do the refurb/rebuild.
Buy the seal kit from Amayama and refurb the rack myself, never ever done this so not kean on this option.
More or less the same options for the steering pump if needed, new pump, have existing one refurbished or rebuild it myself. I would be quite happy refurbing the pump myself.
If anyone has experience of rebuilding the steering rack or the pump or advice in general I would be grateful.
Thanks in advance.
 

[Malc1]

No advice from me BUT I’m aware on some models the leaking drips onto the alternator and “ kaput “ 

Happened to me long way back on my first Mk1 on the M20 at night in the rain 😰

Good luck sorting the issues 

Malc 

[hockeyedwards]

You can get cheaper units from rockauto thats for sure, but they are remanufactured, obviously have to check OEM part numbers.

I've heard mixed reviews on DIY-ing with the seal kit. The rack is apparently quite easy to remove though.

[Razor61]

1 hour ago, hockeyedwards said:

You can get cheaper units from rockauto thats for sure

Good shout, I forgot about RockAuto.

[Razor61]

RockAuto is approx £500 for a recon steering rack, the leak is small and the boot was not full of fluid so will keep an eye on the fluid level.
Had a good look around the pump after removing all the air intake. Leak is not massive at all and won’t drip directly over the alternator as far as I can tell. There is a small pool of fluid on top of the pump, pic illustrates this with the red circle and you can see it glistening. You can also see where the reservoir hose connects to the pump with a retaining bracket, red square. Leak could be from the flow control valve O ring. Had a good look behind the pulley and looks dry.
So in view of all that the plan is to order a gasket/seal kit and bearing for the pump plus the reservoir hose and clips. Maybe also order the idle up valve, pipes and clips, not decided on that yet. Rebuild the pump which will solve the pump leak. I’ll price up everything from Lexus tomorrow, if it’s just a few quid more than Amayama I’ll get the stuff from Lexus but I suspect I’ll be ordering from Amayama.
Steering rack can wait until I decide what to do, pump leak is more important to fix initially, then maybe order the OEM seal kit, remove the rack and take it to Preston Power Steering for a rebuild or it’s RockAuto for a full recon steering rack.
Just a side note when doing this, the air filter was manky so fitted a new one I had. The OEM air filter is no longer available in the UK it seems, £50 from Japan though, so it’s a another make in future.

[hockeyedwards]

If you are rebuilding the power steering pump, it is pretty easy with the seal kit, access isn't terrible to remove and taking apart and putting back together is DIY- able and you seem handy enough.

For the rack, US forums pretty much suggest buying remanufactured unit or taking to a professional, at least you get warranty should something go wrong and apparently its not very DIY friendly with 'many hurdles along the way'.

I would also suggest typing 'Toyota' followed by the part numbers into eBay, I have found a lot of parts for mine that way and have all been of decent quality and much better price wise.

[Razor61]

After some more thinking and talking to a steering rack/pump specialist, parts ordered to rebuild the steering pump from Amayama plus other bits while I was at it keeping the cost under £150 excluding carriage.
Steering rack can wait for the the time being.
When the pump rebuild parts arrive I’ll rebuild the pump and document the process as best I can, in the meantime I’ll look for a used steering rack to use for a rebuild. Reason being it’s 4 - 5 weeks lead time for a steering rack rebuild.

[Razor61]

Small update on the pump leak, I’m off work this week so have plenty of time.
Rather than try and work out where the leak is coming from I decided to eliminate where the leak was ‘not’ coming from. Cleaned all the areas, went for a drive, black on the ramps and had a thorough look. It’s not the O ring for the reservoir, it’s not the banjo connection to the steering rack, it’s not the connection to the idle up valve, maybe the flow control thing on the top but if it is then it’s a very very very small leak, not the bearing or seal at the front as far as I can see.
Doesn’t look like the leak is from the top or front.
I’m pretty sure it’s at the back and leaking from the O ring where the main assembly mates to the the rear mounting assembly. And even then it’s a small ‘weeping’ leak, I thought about nipping up the assembly bolts but decided against it because I didn’t want to disturb anything and make it worse.
Pump will be rebuilt anyway but I wanted to know where the pump is leaking so when I do the rebuild I can look at that area.
Pic of the O ring and area I suspect is leaking.

[hockeyedwards]

That is exactly where mine was leaking from, I hosed mine down with brake cleaner, went for a spin round the block and confirmed it was there, it had already killed one alternator as it was fairly bad so whipped it off and got it sorted immediately!

Something infinitely enjoyable and satisfying about stripping stuff apart and putting back together, happy rebuilding 🙂

[Malc1]

On 11/11/2023 at 4:33 PM, Malc1 said:

No advice from me BUT I’m aware on some models the leaking drips onto the alternator and “ kaput “ 

Happened to me long way back on my first Mk1 on the M20 at night in the rain 😰

Good luck sorting the issues 

Malc 

You seeee. Leaking from that area ……. Alternator goes KAPUT if you leave it much longer 🥵

and that’s silly expensive to replace 😰

Malc 

[Razor61]

11 hours ago, Malc1 said:

You seeee. Leaking from that area ……. Alternator goes KAPUT if you leave it much longer 🥵

and that’s silly expensive to replace 😰

Malc 

I expect it would go kaput, the leak in mine is pretty small at the moment and will be fixed soon. If it was worse then I’d drain the power steering fluid and remove the pump.
Car has been stood for a few days so will have a look at the leak again just to make sure.

I admit to not checking the power steering fluid level on regular basis like I do with everything else, strange why I haven’t but is very very common according to the specialist. Maybe last checked 18 months ago or when I first bought the car. It was the noise first thing in the morning that prompted me to look at the fluid level. Probably leaking for a long time. If I had checked regularly or had the car serviced regularly the fluid loss would have been noticed and investigated before now. MOT wouldn’t pick it up unless it’s really really bad, but then the car would probably be KAPUT anyway and not drivable to the MOT station…………..

[Razor61]

On 11/16/2023 at 4:34 PM, hockeyedwards said:

Something infinitely enjoyable and satisfying about stripping stuff apart and putting back together, happy rebuilding 🙂

Yep, couldn’t agree more. Not looking forward to removing the pump but looking forward to rebuilding it. I’ve even tidied/rearranged the garage, created a ‘workspace’ on the workshop bench (normally stacked with parts and stuff) and bolted down the vice in preparation😁 Something I intended to do but never got round to it and struggled with the vice on a workmate or the floor, silly really when I think about it.
Sorting the garage was also prompted by watching ‘M539 Restorations’ videos on YouTube, very interesting videos. Worth a look and you may get hooked on it. The guy produces quality interesting videos of rebuilding older BMW’s and bringing them back to life. Not Lexus/Toyota of course like The Car Care Nut but are just as good, the principles of the work are the same and done by a guy who started off as a DIY mechanic who worked in IT, father was an engineer and he quit his IT job to restore BMW’s full time with a YouTube channel. Sounds like me but I haven’t quit my job yet and started a YouTube channel about restoring older Lexus cars🤣……….well not yet anyway😉

[hockeyedwards]

3 hours ago, Razor61 said:

I’ve even tidied/rearranged the garage, created a ‘workspace’ on the workshop bench (normally stacked with parts and stuff)

Careful, that can end up being quite deadly, you may never stop and then all of a sudden you've packed yourself neatly into a box and shelved yourself according to your new alphabetic system 😂

3 hours ago, Razor61 said:

‘M539 Restorations’

An amazing channel, I tend to watch them whilst on hold to HMRC or on a call that I just need to be 'present' for but not contribute towards, amazing what you can watch whilst 'at work'. I nearly bought an BMW touring as the dog-mobile after watching some of his videos.

3 hours ago, Razor61 said:

Sounds like me but I haven’t quit my job yet and started a YouTube channel about restoring older Lexus cars🤣……….well not yet anyway😉

I'll keep an eye out 😉

[Razor61]

I was a BMW guy which is what attracted me to M539 Restorations. Started with a 1976 2002tii in Henna Red, then the following cars - E23 728i manual - Jag XJ 3.6 manual - E28 528i auto - Saab 900 EMS - Saab 900 Turbo - Saab 9000 - E46 318i - 2003 Lexus IS200 as a company car for 4 years - 1996 E36 M3 Evo - E36 318ti compact as a project while running the E36 M3 - 2003 E46 M3 - then the big mistake of trading in the E46 M3 in 2016 for a shiny new M140i in Valencia Orange on PCP which was an expensive mistake in the end after it was stolen, police chase in the West Midlands - stinger, crashed, recovered, ‘repaired’, handed back to me. Then came an Audi A4 2.5Tdi Quattro Sport - IS200 and 95 LS400 - IS200 and IS250 and currently a 98 LS400 and IS250.

 

[Razor61]

8 hours ago, hockeyedwards said:

amazing what you can watch whilst 'at work'.

I couldn’t possibly comment on that🤣

[Razor61]

8 hours ago, hockeyedwards said:

Careful, that can end up being quite deadly, you may never stop and then all of a sudden you've packed yourself neatly into a box and shelved yourself according to your new alphabetic system 😂

Not going to happen, I always build in an exit strategy/fallback/backup plan. Normally it includes passing by the beer fridge on the way out😁

[hockeyedwards]

21 hours ago, Razor61 said:

I was a BMW guy

I was the complete opposite, proper JDM kid (kinda still am), the NeedForSpeed era of gaming got me early and hooked! I get more enjoyment looking at 'old japanese tat' as my dad calls it, than most modern stuff.

I have recently discovered, I quite like my new dog-mobile which kinda came out the blue considering I was looking at Alpina/ BMW tourings... I bought a V70R!! 😂

[Razor61]

Well………….went out this morning to put the car on the ramps and check the steering pump leaks. Car wouldn’t start, turned over ok but not fast at all with symptoms of a drained Battery. I immediately decided to remove the steering pump, couldn’t take the risk of knackering the alternator. I suspect all the diagnostics of starting, going for a short run a few times and checking for leaks then leaving for 4 days have drained the Battery. Of course it was peeing down but cracked on with removing the pump after removing the Battery and putting it on charge - it took 6 hours to charge fully, pump is off the car now though.
In theory removing the pump is straightforward but getting a good grip on the rear mounting bolts is a challenge due to getting a socket and ratchet on square without rounding the bolt head which I 100% did not want to do. Lower one was no problem but the top one took me an hour or so taking my time and needed a 1/2 breaker bar with 3/8 adapter and socket to crack it loose. All due to the access under the car on ramps, pipe work in the way and getting p1$$ wet through in the process.
I looked at the alternator and it was dry with no signs of steering fluid in it all so I probably would have been ok charging the Battery and driving the car until the seal kit and other stuff arrived, I didn’t want to chance it though.
The pump……
The O ring on the reservoir connector has been leaking 100%, I could see corrosion on the pump round that area. My original diag where it is was leaking is also correct plus round the bearing and the flow control valve area didn’t look great.
Car will be off the road until I get the rebuild kit and other bits for the pump. I didn’t document stuff cos of the urgency of the job but did take pics of where stuff goes for my benefit.
What pics I did take are below.

 

 

Area of corrosion under the bracket for the resavoir connector after cleaning up a lot with degreaser, carbide scraper and scotch pad. Before it was pretty bad to be honest.

 

 

 

 

 

 

[Malc1]

Well done 👍 

Malc 

[Razor61]

1 hour ago, Malc1 said:

Well done 👍 

Malc 

Thank you, it was Tw@1 of a job tbh in the pouring rain. Of course a ‘dry’ garage with a 2 or 4 post lift would have made life a lot easier as with most jobs but where is the fun in that🤣 DIY mechanics on the drive with run up ramps, axle stands, pi$$ing down and not a lot of room to wield spanners is where it’s at😄

[Razor61]

Regarding the steering rack slight leak, refurb takes 4 - 5 weeks, steering rack is discontinued so can't buy new in the UK, I've enquired with Amayama if they can supply one (approx. £1100 delivered plus duty etc.) just out of interest. I don't fancy rebuilding it myself, pump not a problem but not the steering rack. I could just leave it, it's just a slight leak, and keep an eye on the fluid level. It may not get a lot worse but I suspect it will.
My preferred option is to buy a decent used steering rack, have it refurbished and swop it out. Then maybe have the original one from the car refurbished and sell it to someone who needs one, probably won't work out like that but it's an idea.
So if anyone on here has a decent used steering rack or knows where there is one for sale then please let me know, it would be appreciated.
It has to be a mk4 07.1997 - 08.2000 steering rack.

[John N]

Just go on eBay and put this in the Search Bar - 

Lexus LS400 1996 to 2000 Power Steering Rack Remanufacturing / Repair Service

£325 for a refurbished one.

[Razor61]

8 hours ago, John N said:

Just go on Ebay and put this in the Search Bar - 

Lexus LS400 1996 to 2000 Power Steering Rack Remanufacturing / Repair Service

£325 for a refurbished one.

Already seen that, it’s a repair service and reviews are a bit mixed, first thing I did was search on eBay and Facebook etc. As mentioned earlier in the topic I’ve already found a specialist near me in Preston to do a rebuild.

[Razor61]

The latest on this issue.....
Removed the alternator last night, it looks dry inside with no signs of fluid but I'm getting it checked at a specialist anyway to be sure.
Alternator is a Lexus/Toyota part# 27060-50230 - Denso 101211-7761, after being checked I'll fit it back on the car.
Waiting for the new pump seal kit and bearing and I'll rebuild the pump myself or have it done at a specialist, not decided which yet.

Steering Rack:

A new steering rack part number - 44250-50140 is no longer available from Amayama, which I expected.
A possible replacement is available though - part number  - 44250-50130 and listed for a Toyota Celsior




I've cross referenced parts numbers between the 2, inner/outer tie rods, seal kits, solenoid, the internal bits, bushes etc etc and they are the same.
So I'm pretty confident the possible replacement rack part number  - 44250-50130 will be perfectly ok, if I wanted to shell out for a brand new steering rack @ £1200 - £1300

However, yesterday ACD Lexus Breakers in Accrington got back to me and they had a used steering rack from a 1997 (low mileage apparently). No way of knowing if it's from a late mk3 or early mk4 but I bought it anyway. I suspect it's from a Mk3 but can't be sure. They look identical, the outer bits (tie rods, boots etc) are the same part numbers but the assembly itself is different part numbers. I can't tell the difference between the 2 and the used rack has no signs of leaking and the tie rod ball joints are in excellent shape with good resistance when moved rather being sloppy. Maybe it is a low mileage rack. I've contacted Lexus Customer relations to ask if I can use a 94-97 rack on a 97-2000 LS400, it's worth a shot.

 So I have a few options now

1. Buy the new 'possible replacement' rack mentioned above😬
2. Have the used rack I bought checked out at a specialist, sorted if needed, fit to the car and carry on with it.
3. Fit the used rack to the car, have my original rack refurbished at the specialist (4 - 5 weeks) and fit to the car when done (this only allows me to use the car while the original rack is sorted)
4. Fit the used rack to car and just carry on with it, if it's all ok etc when fitted.

Some more thinking to be done and decide what best to do🤔

[Malc1]

You do have another car to use  while all this is going on ? 

Malc