Hey guys. Hope you're all well. 

My 1983 breadvan has developed a clunk. Does it full lock to left and right, and again when wheels are coming back to straight from full lock in either direction.

Running H&R cup kit, (about 3 years old, 4-5000 miles,) arb blocks that were fitted just before H&R cup kit. Car was lowered when i got it, stock shocks and chopped springs at front, ta technics coilovers on rear. Was also running banded 13 inch steels. Also track rods were replaced end of last year for Lemforders.

I'm currently running mk2 golf steels. 

I've jacked the car up, checked for play on both front wheels, side to side and top to bottom, both were clear, got under it and can't find or see any loose components. Only place there is ANY play, is the bolts on the tie rods. (I think they are the tie rods anyway.) I think the bushes may be tired. They look knackered! There is literally just the tiniest bit of movement when i move them by hand, more than anywhere else on the steering/suspension. 

I do get a clatter coming down off speed bumps but i think that may be the bottom two coils on the springs meeting. 

If this is the part that is on the way out, what would i be looking for to replace it? Then? However those bushes self identify.

Are there any other checks i can do myself to rule stuff out or confirm? 

Thanks for stopping by and reading my essay. Much appreciated.

Keep safe.

get  a helper to move the steering and put your hand on the suspect items to see if you can feel the clonk

 

is the rack tight to the body?   spring ends clonking in the cup?  

Edited 16 June, 20215 yr by steveo3002

I should be able to wrangle a helper tomorrow....

Springs seemed to be seated correctly in the cup at the bottom. 

When it's on the ground, the gap between the bottom few coils is literally just single figure mm's so i'm fairly confident that the clatter is the lower coils contacting each other. 

I'll get the lock test with a helper done and report back. 

Thank you. 

I've just realised, completely by accident, looking at some pictures of H&R cup kit, that my front springs may have been fitted upside down. I have the tighter coils, with the smaller gaps between them at the bottom. Is anyone able to confirm this as if that's the case, i need to go and poop through my mechanics letterbox!!!!

PS, if that IS the case, feel free to point and laugh. 

I been up half the night lookin at pictures and reading things on google and the more i think about it, the more it makes sense that they are upside down. 

Because of the spring length and shock size, is it possible to just undo the top mount nut and the tie rod bolt to sort it, or am i looking at taking whole strut off again?

Clunk is steering rack. Think i've found one but i don't know for sure just yet. 7zap has two different part numbers:

868419065

867419065

Searched for both. Both searches came back with mostly LHD options. Chasing the first number, i found this one:

https://www.heritagepartscentre.com/uk/172419063-steering-rack-for-right-hand-drive-for-non-power-steering.html

I'm waiting on a call back from Heritage parts as the listing doesn't say it fits a polo. 

Chasing the other number got me here:

https://www.onlinecarparts.co.uk/era-benelux-2456075.html

I'm waiting to hear back from that site to find out if it's LHD or RHD. As the listing says it will fit.

 

 

867419065 is LHD. 

868419065 is RHD.

Does anyone know if one from mk1 golf/jetta/scirocco is cross compatible? That one from heritage parts comes up every time i search that part number, (868419065,) but it doesn't mention polo in the listing. Doesn't even give a measurement to go by. Think i need a 558mm one. 

Turns out they aren't cross compatible. Properly struggling to find one at this point. I've contacted refurbishing place to get an idea of cost if i go down that route.

Yeah, the racks are polo specific unfortunately. There was a revised version when the MK1 got facelifted in 1977? But all versions after that before the 6n are the same.

 

It's a very long shot, but have a quick look for any play where the bracket that holds the inner steering arms bolts onto the rack, and again in the column itself. It's probably not the cause, but worth a look. 

 

Any second hand unit is going to have some slop in unfortunately, so you're doing the right thing in getting a refurb done. It might be worth buying a second hand rack and sending that for refurb, so you can keep your car in one piece until it's finished.

Hi. Thanks for that.

 

I got a quote for a refurbed one for £590 delivered. Needless to say i didn't jump on that one!

 

I have found a guy on fb that claims to have one not refurbed, and only wants £55 delivered! What a jump! So i'm gonna jump on that one and like you said, send that away to be rebuilt. Been quoted about £145 for a refurb job. Unless gearing teeth are knackered, in which case it's useless.

 

Thanks guys. 

 

 

If i go down the route of refurbing a second hand unit, which is looking most likely at this point, do i need any other parts for when the refurbed part gets fitted? Tie rods? Bushings? 

I'd say it can't hurt to change the steering arms. Not essential unless yours are in a bad state, but they're cheap enough. Just make sure you get right hand drive ones.

 

If your ball joints and inner bushes are in good condition. It's worth taking the adjustable/nearside arm off and freeing up the joints on it on the bench while it's off the car. Just saves a lot of swearing when you go to do the tracking after the new rack is fitted.