Removing the power steering lines from the rack (or not)

If anyone has any experience of the power steering rack in cold countries where salt is used, you'll probably know that the salt buggers up the lines on the rack just like everything else. So I thought I would take mine out on the C4S, clean the rust and paint them for protection. However, the high pressure and low pressure lines will not come out of the end of the rack. And I mean, WILL NOT. They are held in with a single pan head hex bolt and a clamp. With a lot of wrangling, I finally free'd the bolt (a new one will be required as I ruined it removing it). So that should allow the lines to just pull out as they only have O-rings on them. I've pushed, pulled, rotated and tried to pry those lines out (to the right of the bolt hole in the picture) but to no avail. They will not budge at all. The only thing I can do, is rotate them in the socket if I put some vice grips on them, but even that requires an inordinate amount of force. Does anyone have any good ideas on how I can get them out, or better yet, experience? Parts 1 & 2 in the attached diagram. You can see the o-rings and the clamp part 12 that is now off.

I feel your pain. I have just been through this myself. I don't have anything positive to say I'm afraid.if you have twisted the pipes or fittings you will likely find the pipes will now leak at the join of pipe and fittings. I ended up cutting my pipes off in order To get the rack out. I was then able to eventually remove both fittings from the rack. With lot more twisting and hammering ! The bad news is that there does not seem to be any other source for the pipes than Porsche. Breakers yards don't have them for the very reason that they often don't come out , so no second hand source of parts. I am still looking into options . One of which is to get the lines repaired by a hydraulic shop. Stumbling block is i don't know if the fittings can be sourced. 997lines might be an option . The LHD rack lines are cheaper too , I have a rhd which are more expensive. Anyone with further knowledge please do share.

One more thing if you have some better pics of your lines and how they are routed that would be great . I would like to see how different they are to my c2 . As C4 lines would then be an option.

Nevermind... re-read your post and didn't realize part #12 was removed.

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That doesn�t sound encouraging Laurence! Damm. so far I have managed to not damage the lines I think so they are still in and I have a new retaining clip and bolt on them. I too was considering new pipes but they are crazy money as you say.... actually I think the 02 on pipes that I have in my 04 RHD car are more than the pre 02 ones... that�s on design 911 anyway. I was also also looking for a shop that could make up some pipes for me so if I locate one i�ll Let you know also. I�ll get some more pictures later and put them up anyway.

I wont mention the price i got quoted from Porsche. You'd need to be sitting down with a strong coffee or maybe something stronger. I If you haven't got far with the rack removal I'd advise you stop, put stuff back and lower the sub frame instead to do the transfer pipes. My rack is out so i have no choice. If the you have been able to twist the fittings there is a strong chance that when you start up it will leak at the fitting . The pipe into the fitting is some form of interference fit and goes in about half way down the fitting . It's sealed in some way (fitting to pipe) when you twist the fitting and the pipe stays still you run the risk of that seal /fit leaking . I will try and post some pics up so you can see. For info for others the 997 lines are shorter and it's possible to "join" these to the existing pipe Part numbers 997 347 564 and 997 347 462 03 996 C4 lines 996 347 452 27 and 996 347 450 27 are a direct replacement for C4 and maybe C2 I have contacted Pirtek about making up the short pieces of the lines but as yet no reply. The end fittings are available in the US as an adapter to -6AN fittings but i'm not sure (just looking the pics) if they have the valve installed in the pressure line like the originals. I will email to find out. Company was RSR something they are mean't for electric pump conversion. Hope this helps.

the bits you can't see !!

A little hopefully useful update. The fittings are all made by VOSS not sure which fittings they are but possibly System 291? (for the ones going into the rack. The tubing is marked Hycot which i think is an aluminium coated tubing . .

Those photos are certainly useful Laurence. I can see what I'm up against. ... you really did have to destroy them didn't you! For now I have left it alone and put the new clamp back on but that isn't going to be ok forever as the hard lines that are actually on the top of the rack are very corroded and I'm sure will start causing problems of their own before long. Plus I have a crack in one of the joins of those problem pipes already anyway... looks like it's been there for a while. I spoke to Pirtek also to see if they could make some pipes up for me but they basically just said "sorry too hard". Might have a ferret around on breakers sites and see what I can find there. Design 911 have them but they are �277 and �349 currently for my RHD 02- . If you have an early LHD the price is astronomical. For information of anyone reading this, here are the parts (1 and 2 in the diagram).... https://www.design911.co.uk/pages/di...diagramID=2639

You may consider converting to an electric pump, but that's another story in itself. I converted my track car and have the set of stock front pipes available from a 35k mile chassis left hand drive if that matters. I would entertain offers. Shipping to the UK may be a issue though, they are long.

I have purchased 997 lines from Porsche (�320 the pair) I will still need to get a bridging piece made up. This will then basically copy Porsches 997 lines, which split the lines into two parts for each line. This then means no having to drop the subframe to get the lines out. . It's quite a lot of work though . Breakers don't tend to have the pipes as they can't remove them either and they end up cutting them out. Do a google search on 996 power steering rack and view the images , dozens of racks and lots of pictures of cut off pipes often still in the rack! Even noticed one with the ball joint pin bush stuck on the toe arm (another popular sticking point. No oe manufacture either which is a shame as the price is ridiculous for the original pipes (especially as they could also end up being single use too). I was removing the rack to replace the corroded transfer pipes too. It would appear the best way to do this is to leave the rack in and drop the sub frame to get access, which is a lot more work but not difficult. Just to add this is for RHD steering racks.

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Hi Laurence, how did you get on with this? I gave up in the end for now but I know I will have to tackle it one day. Thinking I will just have to suck it up and buy the parts and destroy the old ones.

I removed mine with ever so light persuasion with a snap on air chisel. It didn�t damage the tubes but got the rusty ones out.

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I am currently taking out the rack for refurbishing and my lines were completely stuck. Managed to get the big one out after some hammering, but the small one has not moved at all. Will have to cut it to get the rack out... So is the best way to solve this getting 997 lines then? @Laurence Gibbs Where is it that you bridge them together?

I know this solution might not sound as a good one but what about converting the existing rack to a manual one? I did this on my old racing car and never looked back!

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I just spent 22k on a new power steering pump, so no but I would maybe have considered it if I knew what a pain and the expenses of it. I just want it to work like original for as cheap as possible at this point...

There are now some fittings that allow you to make up lines to the rack . https://www.facebook.com/groups/996o...83689008541180 hopefully you can see this link . If not join the FB group 996 Carrera owners .

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Thanks, much appreciated!

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I got these in the mail now, but when I got them I realized that the old smaller (return?) plug had a pressure valve inside of it, and the new plugs does not. Could this be a problem? The new plugs say they are made for electric pump, but I don't really see how that would make a difference.

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h hi i changed the two metal pipes in about an hour and a half . first remove o/s wheel rhd car, decide which pipe goes where then bend and snap off rusty pipes .remove unions whith 12 m hex socket .remove anti roll bar and take out ,crack pipe unions with 12 mm open end and loosen ,remove lower rack securing set screws and push rack to rear of car . removal of pipes is made easy .fit new pipes in reverse order . hope this will help you and others. new formed pipes are about �50.00

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Thats great to know and i hadnt thought it was possible that way. I now have a second set of popes to do in my bixster . Will give ot a go.