Performed an autopsy on my Steering rack. 74 Weld case with original Hoss 3.0 internals. My first 74 Weld case was warrantied and they swapped my internals into a new 74 Weld case. This new rack started making a sound racks shouldn’t make on a full lock turn months later.
Ford said “yup” racks gotta be replaced. I had like a week before my Mojave week, so I bought a new Ford 3.0 rack and had them install it. What a mess that was, but I still needed to return a core for a $400 deposit.
I just found time to perform an autopsy and swap internals out of 74 case into my original Hoss 3.0 case. The problem became apparent as soon as I removed the end of my case. The belt connecting the motor to the rack was broken and wadded up.
Disassembled the rest of the rack and found there were no other issues. Nothing loose or binding. No water intrusion. Nothing
So either the belt failed or the tensioner cam was not tensioned properly. It is impossible to tell if it was improperly tensioned when installed (74 Welds fault) or the belt failed on its own (Fords fault). No one will own it, so I’m stuck in the middle.
So I bought a $3000 OEM rack, that ultimately could have been repaired with a simple belt without even removing the rack from the car. Oh well. Moving on.
P.S. I haven’t been able to find that belt yet other than a friend offered me a used one.
The belt as I found it upon pulling the case end off. Not sure why it made noise only at full lock.
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The failed belt
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Frayed belt bits in the end case
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The steering rack end case on installed rack. Remove tie rod, the frame mounting bolt and 7 case bolts and the belt and tensioner are very accessible
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Handwritten notes included with the core return are always appreciated.
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