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Steering rack clunk - cannot solve #4476563
08/01/17 01:57 PM
08/01/17 01:57 PM
Joined: Jan 2009
Posts: 2,460
Rochester, MI, US, World
Klutch9 Offline OP
Klutch9  Offline OP
Joined: Jan 2009
Posts: 2,460
Rochester, MI, US, World
Our Fusion has this clunk that comes from the steering rack. The noise almost sounds like a gearbox with play. I can only replicate it when the car is still, and I shimmy the wheel back and forth quickly. I'm not sure why I ever did this in the first place, but it's been like this for awhile. Today I finally got around to taking some things apart, and checked for bad parts. Both inner and both outer tie rods are good - no play, no broken boots or bellows, no clunks. I disconnected them on the outer end to test, so the parts were unloaded. Even when the tie rods are hanging free, the noise is still present. I checked the steering shaft/joints, and those too are good.

What I did see, where the shaft stub comes through the floor, is that it will wiggle back and forth the tiniest bit if you try and move it. Is this normal? I really have no experience with power steering racks, and how much play they should have. Rack mounts are in good shape also, FWIW. This is also a fully electric rack. Car drives and steers fine, with seemingly no play or noise under normal driving.


'11 Fusion SE 2.5L - 79k miles - HK 0w20 syn, Wix XP filter
'08 Sedona LX LWB 3.8L - 126k miles - Havoline HM 5w20, Auto7 filter
Re: Steering rack clunk - cannot solve [Re: Klutch9] #4476616
08/01/17 02:55 PM
08/01/17 02:55 PM
Joined: Jan 2004
Posts: 4,142
California
nthach Offline
nthach  Offline
Joined: Jan 2004
Posts: 4,142
California
There should be some preload on the rack and pinion but its hard to measure that in the car. I'm thinking either the pinion bearing/bushing has some play in it or the steering shaft has some slop at the splines/coupling or at a joint.

Re: Steering rack clunk - cannot solve [Re: Klutch9] #4476664
08/01/17 03:43 PM
08/01/17 03:43 PM
Joined: Jun 2005
Posts: 11,316
Santa Barbara, CA
bdcardinal Online content
bdcardinal  Online Content
Joined: Jun 2005
Posts: 11,316
Santa Barbara, CA
It could be the rack itself. I went through the ROs where we replaced racks on your year Fusion but all the descriptions were for either complete loss of power assist, or a light on and towed in.


2014 Ford Mustang GT Track Pack
1995 Ford Mustang GT

Ford/Mazda Parts Counter
NRA Benefactor Member
Opinions expressed are my own.
Re: Steering rack clunk - cannot solve [Re: bdcardinal] #4476668
08/01/17 03:51 PM
08/01/17 03:51 PM
Joined: Jan 2009
Posts: 2,460
Rochester, MI, US, World
Klutch9 Offline OP
Klutch9  Offline OP
Joined: Jan 2009
Posts: 2,460
Rochester, MI, US, World
Originally Posted By: bdcardinal
It could be the rack itself. I went through the ROs where we replaced racks on your year Fusion but all the descriptions were for either complete loss of power assist, or a light on and towed in.


Is there a way to adjust preload on this unit?


'11 Fusion SE 2.5L - 79k miles - HK 0w20 syn, Wix XP filter
'08 Sedona LX LWB 3.8L - 126k miles - Havoline HM 5w20, Auto7 filter
Re: Steering rack clunk - cannot solve [Re: Klutch9] #4476690
08/01/17 04:13 PM
08/01/17 04:13 PM
Joined: Jun 2005
Posts: 11,316
Santa Barbara, CA
bdcardinal Online content
bdcardinal  Online Content
Joined: Jun 2005
Posts: 11,316
Santa Barbara, CA
No adjustment that I can see listed.


2014 Ford Mustang GT Track Pack
1995 Ford Mustang GT

Ford/Mazda Parts Counter
NRA Benefactor Member
Opinions expressed are my own.
Re: Steering rack clunk - cannot solve [Re: Klutch9] #4476701
08/01/17 04:24 PM
08/01/17 04:24 PM
Joined: Nov 2006
Posts: 19,895
MA, Mittelfranken.de
Trav Offline
Trav  Offline
Joined: Nov 2006
Posts: 19,895
MA, Mittelfranken.de
You may need a rack, I use a good place that builds perfect racks with a great warranty, not cheap junk. PM sent.

http://www.jorgenauto.com/index.html

Last edited by Trav; 08/01/17 04:30 PM.

ASE L1, Master. Deutsch Meisterbrief.
Re: Steering rack clunk - cannot solve [Re: Klutch9] #4476709
08/01/17 04:34 PM
08/01/17 04:34 PM
Joined: Sep 2012
Posts: 5,378
DFW
DBMaster Offline
DBMaster  Offline
Joined: Sep 2012
Posts: 5,378
DFW
I know that Escorts are not the same as Fusions but I had very similar issues, worse actually, when the steering rack bushings needed replacing. They were basically rubber inserts that fit inside the metal brackets that secured the steering rack to the body/frame.

Re: Steering rack clunk - cannot solve [Re: Klutch9] #4476814
08/01/17 06:49 PM
08/01/17 06:49 PM
Joined: Aug 2004
Posts: 1,947
5600 feet elevation, Arizona
double vanos Offline
double vanos  Offline
Joined: Aug 2004
Posts: 1,947
5600 feet elevation, Arizona
For years Chevy trucks had an Intermediate Steering Shaft clunk which, among other things, caused me to switch to Ford Pickups. It is aggravating as all get out. Could this be it? When my first one was replaced under warranty on my 2005 Silverado the service writer informed me that they had over 300 in stock and replaced them like popcorn. I haven't driven a Chevy since: I wonder, did they ever get that fixed?


Sabine Schmitz is the Queen of the 'Ring; Svetlana Kapanina is the Queen of the SKIES...
Re: Steering rack clunk - cannot solve [Re: double vanos] #4476832
08/01/17 06:57 PM
08/01/17 06:57 PM
Joined: Nov 2006
Posts: 19,895
MA, Mittelfranken.de
Trav Offline
Trav  Offline
Joined: Nov 2006
Posts: 19,895
MA, Mittelfranken.de
Lots of GM cars had that problem all the way back into the 90's, I don't think they ever got it squared away 100%.


ASE L1, Master. Deutsch Meisterbrief.
Re: Steering rack clunk - cannot solve [Re: double vanos] #4476835
08/01/17 07:01 PM
08/01/17 07:01 PM
Joined: Sep 2010
Posts: 6,987
Texas
4WD Online confused
4WD  Online Confused
Joined: Sep 2010
Posts: 6,987
Texas
They went to rack & pinion ...

Re: Steering rack clunk - cannot solve [Re: Trav] #4476961
08/01/17 09:18 PM
08/01/17 09:18 PM
Joined: Feb 2008
Posts: 683
Atlanta, GA
RoGuE Offline
RoGuE  Offline
Joined: Feb 2008
Posts: 683
Atlanta, GA
Originally Posted By: Trav
Lots of GM cars had that problem all the way back into the 90's, I don't think they ever got it squared away 100%.


I think you're referring to the intermediate steering shaft clunk. My dads 02 Suburban has it, even my 07 Malibu has it.


2007 Chevrolet Malibu
2.2L Ecotec
Re: Steering rack clunk - cannot solve [Re: RoGuE] #4476964
08/01/17 09:24 PM
08/01/17 09:24 PM
Joined: Sep 2010
Posts: 6,987
Texas
4WD Online confused
4WD  Online Confused
Joined: Sep 2010
Posts: 6,987
Texas
That vintage had recirc ball, right? Now both of my GM's are rack & pinion - one electric and one hydraulic - no noise ...

Re: Steering rack clunk - cannot solve [Re: RoGuE] #4476974
08/01/17 09:40 PM
08/01/17 09:40 PM
Joined: Apr 2010
Posts: 174
Michigan
jkasch Offline
jkasch  Offline
Joined: Apr 2010
Posts: 174
Michigan
Originally Posted By: RoGuE
Originally Posted By: Trav
Lots of GM cars had that problem all the way back into the 90's, I don't think they ever got it squared away 100%.


I think you're referring to the intermediate steering shaft clunk. My dads 02 Suburban has it, even my 07 Malibu has it.


Yup. The spline sticks and slips making annoying clunk. Lubing works for a while, but it seeems to always come back.

Re: Steering rack clunk - cannot solve [Re: RoGuE] #4477007
08/01/17 10:30 PM
08/01/17 10:30 PM
Joined: Nov 2006
Posts: 19,895
MA, Mittelfranken.de
Trav Offline
Trav  Offline
Joined: Nov 2006
Posts: 19,895
MA, Mittelfranken.de
Originally Posted By: RoGuE

I think you're referring to the intermediate steering shaft clunk. My dads 02 Suburban has it, even my 07 Malibu has it.


Double vanos said..
Quote:
For years Chevy trucks had an Intermediate Steering Shaft clunk


To which I replied..
Quote:
Lots of GM cars had that problem all the way back into the 90's


Is there a question as to what I was referring to?


ASE L1, Master. Deutsch Meisterbrief.
Re: Steering rack clunk - cannot solve [Re: Klutch9] #4477097
08/02/17 04:56 AM
08/02/17 04:56 AM
Joined: Feb 2013
Posts: 3,226
Central Virginia
Silverado12 Offline
Silverado12  Offline
Joined: Feb 2013
Posts: 3,226
Central Virginia
I had the intermediate shaft clunk in a Dodge truck without rack & pinion steering. I just greased it and it went away.


12 Chevy Silverado ext. cab LS, 2WD 4.3 auto
18 Mustang GT 5.0 auto
07 Harley Dyna Street Bob 96 c.i. 6 sp.
00 Mustang GT auto

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