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I have a 1994 940 turbo wagon -- VIN:
YV1JW870XR0100136
It is leaking steering fluid from the passenger side boot on steering rack. Trusted Volvo repair shop say I need a new rack -- BUT they can't locate one for me. They say that I need a part number 5003682 and that this original part is a Koyo.
I am also having trouble locating the right part. If the part number is 5003682 and make is TRW -- would this fit my car?
In any event all the dealers seem out of stock. Any ideas on how I can procure the right part? Ebay? Junk yards? Steering rack rebuild specialists? Could this be the end of the line for this car?? (I hope not). Any encouraging comments would be welcome --
Rob
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Dear rob2volvos,
Hope you're well and stay so. Koyo and TRW racks do not interchange. You could substitute TRW for Koyo if you also changed the hoses - from the power steering pump to the rack - tie rods, and tie rods ends,
But there's no need to do that. According to the catalog of Maval - a high-quality rack re-builder - their part number for the Koyo rack is 9259M. The part number (9017M) is for the CAM/TRW rack.
This seller represents that s/he has one such rack. I'd verify by Maval part #, that they have the correct item: https://www.ebay.com/p/114971960 . Some think that "one size fits all" applies to Volvo 940 racks. That's simply not so!
Alternatively, www.cardone.com - a rebuilder of many types of car parts - has a re-build service that requires a parts house to send your car's rack to them. Cardonel re-builds it and returns it to your chosen parts supplier, see: https://www.cardone.com/randr . If there's no parts supplier near you, that works with Cardone, www.rockauto.com can serve as your gateway to Cardone's rack rebuilding service.
I recall Brickboard posts that described putting a TRW rack into a car set up for Koyo or vice-versa. The process involved bending the rack ends of the power steering pump's hoses, so that the steel fittings could be secured to the rack body as tightly as required. Do that would be the last resort.
Hope this helps.
Yours faithfully,
Spook
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Thanks Spook. I hope you are well too, and staying sane in these crazy times. Great information. Part of my confusion is that I am informed by the mechanic that the make of the original steering rack is Koyo, but that the replacement part number is 5003682. Then I see advertisements for TRW racks of part number 5003682. I gather from your comments that the manufacturer here is more significant than any part number when it comes to replacement.
Well, whatever, this is going to take some time. While I look around for options I'll put the car on the ramps in my driveway and think about getting it off the car and establishing that it is indeed a Koyo.
Rob
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Dear rob2volvos,
Hope you're well and stay so. To know if the factory-installed rack is a Koyo product, look at the data plate on the upper radiator cross-brace. This data plate is to the right of the radiator, as you face the engine bay.
This data plate has two columns: a wide left-hand column and a narrow right-hand column. In the last row of the narrow (right-hand) column, at the end of that bottom row, there's a single digit. If that digit is "1" the rack is a Koyo unit. If that digit is "2" or "4", the rack is a CAM/TRW unit. If the digit is "3", the rack is a ZF unit.
Unless you're the first and only owner, or if not - if you have all maintenance records - the data plate's rack indicator digit is dispositive: you'd recall having replaced the rack with one different from that indicated on the data plate, or having seen a rack replacement in the maintenance records.
You don't have to remove the rack to ascertain its maker. The rack has its own data plate - possibly covered in dirt - which is visible once you remove the splash shield.
The rack data plate on my 940 with a Koyo rack reads: KOYO, #23250077; VOLVO # 6819225.
Some parts databases may use the "5003682" part number to refer to KOYO or CAM/TRW racks, but require a supplementary note as to the factory-installed rack's maker.
From the fact that MAVAL - a top-notch rack re-builder - has separate part numbers for Koyo versus CAM/TRW units, I infer that those units are different and incompatible.
Hope this helps.
Yours faithfully,
Spook
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Hi Spook --
Very helpful stuff. Having crawled under the car with a flashlight, paper and a pencil -- Here is what is on the label on my steering rack:
Volvo
6819225-5 LH
32020 120
Koyo
Japan
In other words, I think I have the same one as you. Since you are complimentary of MAVAL, perhaps my best bet is a MAVAL aftermarket. Do you happen to know the identification number of the correct MAVAL model?
All the MAVAL supplies seem to be backordered currently -- none available (covid effect?). Another possibility is CeeBee1's suggestion of http://www.voluparts.com (the Atlanta group). They have replied to my emails and may have a rebuilt unit for $335. I don't mind the money so much as knowing that it will fit!
Then, while I wait there is jwalker's suggestion of flushing with high quality ATF to reseal the leaks.
Thanks, Rob
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Dear rob2volvos,
Hope you're well and stay so. The Maval part number - for a rebuilt Koyo rack - is 9259M.
Before tackling a rack replacement, I'd do as jwalker urges: Buy a couple of quarts of Mobil 1 Synthetic Automatic Transmission Fluid (ATF), and flush the system. The Mobil 1 ATF may cost $13/quart. It is worth the money, if it solves the problem.
And if a flush does not cure the leaks, you've still cleansed the system, i.e., hoses, pump, and reservoir.
I emphasize the use of Mobil1, because the price difference between Mobil1 and a "high quality ATF", is not so large as to make worthwhile the taking of risks. If Mobil1 solves the problem, you've saved hundreds of dollars. If you use some "high quality ATF", and the rack still leaks, you'll spend those hundreds of dollars.
Hope this helps!
Yours faithfully,
Spook
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OK, Spook -- I just ordered some Mobil1 ATF.
Might as well -- I'm going to have to wait until a decent replacement rack becomes available. I'll update this thread on the progress, and what I wind up doing to solve this issue -- Rob
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Hi Rob,
You have a few refill options:
1. Buy cheap ATF, flush thoroughly with that and refill with Mobil 1 synthetic ATF.
2. Flush and refill with Mobil 1 ATF.
3. Gradual replacement method. Using a turkey baster, siphon out as much as you can then top up with the Mobil. Do this 3 or 4 times and you’ll essentially have converted to synthetic.
One caveat - be aware that at first the synthetic might cause the seals to leak worse. Hang in there, the leaking will abate fairly quickly.
Jim
--
Will I buy another Volvo??? We'll see....
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call the Atlanta boys. Phone or email---
http://www.voluparts.com/
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Resolution --
Yep! The boys at
http://www.voluparts.com/
were able to come up with a Maval 9259M -- as predicted and diagnosed by Spook.
close to $400 for the part (with shipping), $250 for labor at a workshop I trust. They asked "where did you GET this?" I told them my sources were from brickboard.com. Another satisfied customer -- Thanks, Guys!!
Rob
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Thank you Sir -- I was unaware of this group, I'll see what they say. Looks like a good option to have in your back pocket if you have an ageing Volvo.
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Often it is just the rack seals leaking. Before condemning the rack, I suggest flushing out the old fluid and refilling with Mobil 1 Synthetic ATF or other compatible PS synthetic fluid. Synthetic will clean the seals. The rack seals were leaking on my 95 850. I flushed out the old fluid and refilled with Mobil 1 Synthetic ATF. About a month later the leak dried up…:)
--
Will I buy another Volvo??? We'll see....
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