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clunk in steering rack 05 pacifica
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shotgunboss
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Sep 6, 2010, 9:20 AM
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clunk in steering rack 05 pacifica
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my wife has an 05 pacifica all wheel drive limited with 3.5 liter, we bought the car with just under 50k on odometer, earlier this spring (march) she noticed a clunk when turning wheel side to side (about a quarter turn or so) we brought the car to the dealer they charged us $53 to say that there was a noise in the steering rack, and that it would cost $1000 u.s. to repair, i searched the internet and found rebuilt ones for $300 to $500 range, also found used ones with lifetime warranty for $200, we bought a used one, i put it in and everything was fine for about a week then the clunk came back, i checked the inner and outer tie rods and everything seems tight, the clunk had gotten worse so we decided to buy a rebuilt unit, i replaced the rack and new outer tie rods both sides, the clunk is still there, it is somewhere in the rack, i greased both lower ball joints, i have checked all other suspension components and everything is tight or not broken, my question is what is causing the problem, by the way when i turn the wheel lock to lock, and then rock the steering wheel side to side the problem goes away for a short period (rebuilt rack only) is this clunking due to air in the system? i am using the approved fluid atf+4
if air is in system wouldn't the pump whine? or do i need to replace the rack again? any insight would help thank you
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Sidom
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Sep 6, 2010, 12:16 PM
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Re: clunk in steering rack 05 pacifica
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Disconnect the sway bar link arms from the sway bar to the strut and see if the noise goes away. Just drive it a short distance at slow speeds while the arms are disconnected and makes sure they are secured so they won't hit anything moving while driving........
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shotgunboss
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Sep 6, 2010, 12:26 PM
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Re: clunk in steering rack 05 pacifica
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ok i will try that, would it be the link ends or what? if the noise goes away! you can feel the "clunk" in the rack when rocking the steering wheel side to side while the front of car is raised and supported on jack stands (wheels completely off ground)
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Sidom
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Sep 6, 2010, 12:40 PM
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Re: clunk in steering rack 05 pacifica
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If you can get it to clunk while it's sit there in the air, then it probably won't be the problem I'm thinking of. I've had some Chrys with bad sway bar frame bushing that the clunking was transmitting to other areas but would only do it while driving.....
It's not going to hurt to try this and would eliminate the sway bar & links as a possible problem if the noise is still there with them disconnected.....
If you are feeling it in the rack for sure, there may be a problem with the steering coupler or shaft......
Ok, Ok.....Now you're gonna make me have to go & look thru some TSBs...... Darn it... I was really hoping to get thru today with out having to think........
Speaking of which, this is a holiday..... Shouldn't you be at a BBQ or drinkin some beers or something, instead of working on your car.....
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shotgunboss
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Sep 6, 2010, 1:02 PM
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Re: clunk in steering rack 05 pacifica
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well actually i did the rack yesterday, and was pretty disappointed when the clunk was still there, it is raining here today, so working on it is not an option today, could it be its just because half the unit is aluminum and the other half is steel (which is where the "clunk" is felt, steel housing pass. side)? i will investigate the stab. links, and maybe the coupler? that was a nightmare to get the roll pin out using a hammer and punch the first time so i made a roll pin press which i am in the process of applying for a patent, sure doe's save a lot of time and also eases with removal and installation of coupler to the shaft
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Sidom
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Sep 6, 2010, 1:06 PM
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Re: clunk in steering rack 05 pacifica
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Yea those pins are a PITA. One thing you can try real quick is to grab the coupler and shaft from inside while someone moves the wheels. If the clunk goes away or you can feel it coming out of the shaft that would help to narrow it down....
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Sidom
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Sep 6, 2010, 2:07 PM
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Re: clunk in steering rack 05 pacifica
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There are a few TSBs out there.....None apply exactly to the problem but if the shop is having trouble pinpointing the noise they would really need to be looked at, if for no other reason, to be eliminated as a possible cause...
1 is 02-007-04 which is a low speed clunk due to bad control arms. ( I would look at this one real close )
The other two are 02-004-05 frt strut noise problem & 19-006-05 low speed shudder traced to the p/s. The last 2 are doubtful but still need to be checked out.
I found one TSB I couldn't pull up, maybe Desi can run it thru his database to see if it's an actual TSB or typo 02-001-05 (I think it's a typo for 02-004-05)
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Hammer Time
Ultimate Carjunky
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Sep 6, 2010, 4:11 PM
Post #8 of 12
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Re: clunk in steering rack 05 pacifica
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No, I can't find that number either.
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
We offer help in answering questions, clarifying things or giving advice but we are not a substitute for an on-site inspection by a professional.
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shotgunboss
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Sep 13, 2010, 6:04 PM
Post #9 of 12
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Re: clunk in steering rack 05 pacifica
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after further investigating, i removed the silencer boot up and out of the way from the the floor board and observed the intermediate shaft coupling as i slightly turned the wheel to the right, the intermediate shaft coupling rises up briefly then drops suddenly leaving a thud noise, which i suspect transfers down the lower intermediate shaft then the sector shaft and through the rack itself, my only question is now what needs to be replaced? the u-joint coupling looks and feels in good working order
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Sidom
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Sep 13, 2010, 7:02 PM
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Re: clunk in steering rack 05 pacifica
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That is the real frustrating thing about chasing down noises. Noises will transmit thru other components making it real hard to confirm. Chevy trucks have a problem with their intermediate shafts and clunking noises so once you've had one, diagnosing the next one is a lot easier. The 1st one is always the one that takes a lot of time...
I checked and didn't see anything listing bad intermediate shafts on PTs but that doesn't mean there isn't a problem with it. On noises like this I 1st like to get the noise to stop. Whether you have to disconnect something, loosen, tighten, flip around, wrap a rag around, (this is where chassis ears are worth double their weight in gold) anything to know you're in the right area. Then you just have to inspect the parts real close for any signs of failure....play, cracks, rubbing marks...... It's tough.... In some case you just have to make an educated guess.....
One that got me, an 03 Caravan had a popping noise from the RF on bumps & turns. Another shop had changed the struts & mounts and the noise sounded exactly like a bad strut mount. Everything looked good except the sway bar link bar on the R had a broken boot & the joint had play. I disconnected the bar, drove it and the noise was gone. I replaced the bad link & the noise came back. I had already looked at the sway bay & frame bushings...Tight, no play, everything looked & felt fine. I took the R frame bushing out and it looked perfect, rubber was fine, hole wasn't oblonged....nothing. I put it back in upside down and the noise was gone..... I installed a new bushing correctly and the noise was gone???????
For the life of me I could not see anything wrong with that bushing but a new one fixed it and I've seen this problem about a 1/2 dozen times since on other Caravans. The 1st one took hours to find. The others take minutes to confirm.....
The 1st one sux & will eat your lunch......
(This post was edited by Sidom on Sep 13, 2010, 7:05 PM)
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shotgunboss
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Sep 14, 2010, 4:39 PM
Post #11 of 12
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Re: clunk in steering rack 05 pacifica
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i know what your saying about things that look right but are bad, we have some milltronics vertical mills that have positioning problems on the x axis, due to perfectly good looking drive belts uggh!! but is the rise in the intermediate shaft normal? it looks to be kinda hard for the home technician to replace, only cuz of all the crap thats attached to the power pedals, i had a real hard time getting the boot passed whatever switch is on the left side of the brake pedal, i machined a roll pin press for the lower intermediate shaft, so thats a 3min. job versus an hour plus laying on my back swinging a hammer in a limited space the first time i replaced the rack, does the intermediate shaft just slide out of the steering column? i really dont want to take it back to watertown ford/chrysler as i think there a bunch of idiots!!! and refuse to give them any more of my money, they made my wife feel if she had to replace the rack that day for her safety, i want to go there and just pummel the service managers face in....... i will however get my revenge on them another way!!legally that is
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Sidom
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Sep 14, 2010, 9:36 PM
Post #12 of 12
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Re: clunk in steering rack 05 pacifica
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I haven't had to change one of those yet but it only calls for .5 so I can't imagine having to remove the column for that. More than likely you'll just have to remove the covers, both pinch bolts and should be able to slide it out.
On jobs like this or doing the rack you want to keep the wheel locked so you don't stretch the air bag cable or damage the clockspring BUT while I had the shaft out I would CAREFULLY turn the wheel while hold the end to see if I could feel any binding or popping. keeping note exactly of where the wheel was to start, how far I went in each direction and not going more that one turn in either direction. All this would be assuming the wheels were straight or a close as possible to start with.
I would also want to move the rack while it was disconnected to see if I could feel the noise. Keeping this end lined up correctly is a bit harder so if there was any doubt at all......I wouldn't do it...........
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