Hello, my 2003 S40 with over 160,000 miles on the clock has been leaking fluid from the steering rack, so says my shop. I believe them. It was making a groaning sound when going around corners, otherwise no noise. I used a few Barr's fluids that are sold as a way to "repair" the leak(s) but I have found it might make it better or even okay for a time before it gets worse.

There are apparently no new racks available, only remanufactured ones, and from what I can see, they run $300-$400. Then there is the matter of replacing it or having it replaced. I am in the DFW area and would like to find a free-lance mechanic who knows Volvo who is interested in a side job. I have only a very cramped one car garage that is occupied by another car. I have been quoted about $1,000 for job but for me that is a lot of money right now, but I still need to get it repaired.

Anyone in DFW know such a person? I think the job is beyond my capabilities in addition to the cramped quarters. Anybody have experience with this? Appreciate any and all feedback or help! Help!

Unfortunately for you Brickboard traffic (readership) is way down these days. There never were very many S40 posters. I have seen a few knowledgeable S40 guys but not recently.

Racks don't groan. Power steering pumps groan when turning if worn. They can also groan if the PS fluid level is low. As is your case. Not enough fluid to lubricate the pump. $2000 for a new rack is a ripoff. Your mechanic needs to make his boat payment!

Again, don't condemn the rack. The rack might be perfectly fine. It could be something else. If you are willing to jump in and do some cleaning and research, you stand to save yourself some serious coin. You might find it's a leaky hose or reservoir tank. Perhaps a bad pump or leaky rack seals which can sometimes be rejuvenated by flushing the PS system and refilling with the correct synthetic fluid.

Look, I'll be the first to admit I'm not a mechanic..:)
I don't have experience with S40's but I do know something about Volvo racks. I replaced the rack on my 240 and I stopped the rack on my 850 from leaking by changing the fluid to Mobil 1 Synthetic PS fluid. Doing the work to locate your problem is obviously up to you but you could save yourself significant green....
--
Will I buy another Volvo??? We'll see....

Jim is spot on, $2000 YIKES! Get a new mechanic.

Ebay ad $203.00
Steering Rack and Pinion for Volvo 40 Series 2001, S40 2002-2003, V40 2002-2004
COMPLETE UNIT * LIFETIME WARRANTY * FREE SHIPPING
Item Information
Condition:
RemanufacturedRemanufactured
“Remanufactured in Detroit, MI, USA!

It's not rocket science to replace a rack. Although you'll probably want
a front end alignment. Ask around the local garages to find out who is the alignment ace in your area. Forget chain stores.
While you're at it ask about your rack, get a reasonable quote if you actually do need it from the alignment ace.

Jim's point to flush with new is a great idea, but how exactly?
Maybe unhook an fitting and continue to add at the reservoir with the pump running while catching the old dirt fluid in a pan of course? I have used a turkey baster to remove all the hydraulic fluid I could but that's not a flush. Maybe some heavy hitter can chime in.

I bought my 740 needing a rack- there was a bad leak. When I got it home I de-greased the mess around the rack and found that the rack was fine and the
steel hydraulic line had a pin hole leak. It cost about $42 for the Volvo line. It went in easily, and all was well for short money.

Finally I'm told by a local ace mechanic that if you have leaky seals the magic
ingredient to swell seals is brake fluid. Use only a cap full in the crankcase for RMS and a small amount for the rack. He warns only to use a little. Funny if that's all that pricey commercial RMS treatment is bottle of ordinary oil with a little brake fluid. :-(

Ahoy Jim, send me an e-mail.

Cheers, Bill

I should have said, my shop has quoted me $2,000 for the job but this level of expense falls really badly right now. There has to be a free-lance mechanic who has knowledge of Volvo, after all this car has been on the road for 20 years now and plenty of time for good mechanics to see them come in. Anyone know such a person, please let me know. Thanks, D