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Thread: BMW E39 I6 528i 525i 530i steering rack rebuild

  1. #1
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    BMW E39 I6 528i 525i 530i steering rack rebuild

    Fellas

    We all know that I6 has the best steering rack with pinion
    Based on my experience and research on US/ EURO forums to be able to take the best of them they need to be rebuild every ~100k
    I don't want to argue if it is necessary or not , if you think your steering rack
    is perfect after 100k+ miles this thread is not for you

    So lets start

    1. All I6 has the same steering rack
    The ZF # is 7852 955 304 and it is the same for 528i, 525i and 530i
    ( remember this number 7852 )
    I personally checked 3 steering racks for M54 and they all have the same ZF number
    The BMW # for steering rack w/o Servotronic ( US version ) is 32136751745

    2. For this steering rack 7852 this is what i found so far :

    The parts :

    http://forum.bmwland.ru/index.php?ac...=post&id=26968

    1 bearing ZF 0635 332 003 pic # 2
    1 bearing ZF 7830 327 111 pic #53
    2 plastic bush ZF 7852 035 131 pic # 24
    1 plastic bush ZF 7852 040 192 pic # 30,1
    1 plastic bush ZF 0770197 047 pic # 57
    1 bolt ZF 7830 030 120 pic # 34
    1 seal ZF 7830 040 507 pic # 34.3

    1 seal kit ZF 7852 633 048
    This what is included into this kit :
    ==================================
    2 seals ZF 7852 033 155 pic # 10.9
    1 seal ZF 0634 303 218 pic # 15
    1 seal ZF 7852 033 166 pic # 16
    1 seal ZF 0634 304 563 pic # 17
    1 seal ZF 0634 306 218 pic # 31
    1 seal ZF 0634 306 233 pic # 38
    1 plastic bush ZF 0770 198 175 pic # 51
    1 plastic bush ZF 0770 198 168 pic # 58
    4 seals ZF 7409 033 112 pic # 87
    4 seals ZF 0770 031 331 pic # 88
    1 seal ZF 0634 303 340 pic # 94
    8 seals ZF 7830 033 163 pic # 103
    ===================================

    The repair instruction for ZF steering rack 7852

    ZF Rack and Pinion Power Steering Gear

    3. I dropped mail to ZF US asking if i can get these parts
    ( anyone tried ? )

    4. One more link is in US kit # RB8623.1 , Rack Kits / 528 / 97-00 / Without Servotronic
    ( anyone tried ? Looks like the one we need )

    http://www.pskits.com/catalog/-c-21_25.html

    Anywhere noone of these kits include bearings

    5. One more source i found in UK

    http://steeringseals.com/5series-2.html

    6 To have idea about this job

    http://bmwpost.ru/forum/showpost.php...83&postcount=4

    Stay tuned
    I
    Last edited by champaign777; 10-07-2012 at 01:06 PM.

  2. #2
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    I have a transmission guy who rebuilds ZF trannies. I wonder if he can get ahold of some of these parts. I will check and post back.

  3. #3
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    thank you sir
    i contacted ZF USA and they said it will take up to one month to get an answer from ZF Germany
    Deutsche Nixt Fershteyn
    Last edited by champaign777; 10-13-2012 at 10:31 AM.

  4. #4
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    Quote Originally Posted by champaign777
    thank you sir
    i contacted ZF USA and they said it will take up to one month to get an answer from ZF Germany
    Deutsche Nixt Fershteyn
    Its worth the wait although mine is pretty bad.

  5. #5
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    Hay Igor,

    This thread is very cool and interesting.

    Subscribed.

    Graham


  6. #6
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    Quote Originally Posted by Graham E39 528i View Post
    Hey Igor,

    This thread is very cool and interesting.

    Subscribed.

    Graham

    +1!
    I agree!
    However, I wonder if the price for ALL of these parts Igor listed above cost just about as much as a rebuilt/ re-manufactured steering rack from BMW / and/ or Vendor...?

    Thanks!
    Jason

  7. #7
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    Quote Originally Posted by Graham E39 528i View Post
    Hay Igor,

    This thread is very cool and interesting.

    Subscribed.

    Graham

    thanks Graham
    lets keep it alive and do this even it was never done in US
    people on this forum did more complicated tasks than this ,
    all we need is correct parts here in US

    Quote Originally Posted by Jason5driver View Post
    +1!
    I agree!
    However, I wonder if the price for ALL of these parts Igor listed above cost just about as much as a rebuilt/ re-manufactured steering rack from BMW / and/ or Vendor...?

    Thanks!
    Jason
    Jason
    The price should be around $120 for all parts including bearings

    The ZF Rack is available today in the States
    $790.32 plus $170.00 core charge plus your choice of freight if you buy directly from zf-usa

    The problem with rebuild rack
    1. its TOO much money for rebuild part if you ask me
    2. you never know which rack was rebuild
    it maybe had already 300k miles before rebuild
    Last edited by champaign777; 10-13-2012 at 04:08 PM. Reason: Automerged Doublepost

  8. #8
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    Quote Originally Posted by champaign777 View Post

    Jason
    The price should be around $120 for all parts including bearings.

    The ZF Rack is available today in the States.
    $790.32 plus $170.00 core charge plus your choice of freight if you buy directly from zf-usa.

    The problem with buying a rebuilt rack is:
    1. It's TOO much money for rebuilt part, if you ask me, and
    2. You never know which rack was rebuilt.

    It may already had 300k miles before the rack was rebuilt.

    I prefer to rebuild my lovely low mile rack myself if it's possible.
    Ok, that makes sense...
    I did not know the prices for the parts you listed above...

    I wonder how hard it would be to take apart your existing rack...?
    Plus, if you are able to get your existing rack open, how long would the procedure take to replace ALL of list parts above...?

    Regardless,
    Rebuilding the steering rack yourself is something definitely to keep in mind IMO...!


    Thanks!
    Jason
    Last edited by Jason5driver; 10-14-2012 at 12:19 AM.

  9. #9
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    This is great. I'm hard core DIY & would love to be able to get these parts.

    BTW, champaign777.... I find your sig to be simultaneously annoying AND irresistably fascinating.
    "The water was not fit to drink. To make it palatable, we had to add whisky. By dilligent effort, I learnt to like it." Sir Winston Churchill

  10. #10
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    The rebuild kit costs about $50.
    http://www.pskits.com/catalog/-c-21_25.html


    Also from the UK for 39.97:

    http://steeringseals.com/kits.html?manufacturer=34&p=3

    -----------

    This is from a Porsche forum, but it is similar idea (ZF Steering Rack), looks like a fun job!

    http://forums.rennlist.com/rennforum...ings-pics.html

  11. #11
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    Quote Originally Posted by e21Terry View Post
    This is great. I'm hard core DIY & would love to be able to get these parts.

    BTW, champaign777.... I find your sig to be simultaneously annoying AND irresistably fascinating.
    hehe there are so many dumps on this forum
    one more dump doesn't make any differences
    but if you ask ... ok i removed it

    Quote Originally Posted by cnn View Post
    The rebuild kit costs about $50.
    http://www.pskits.com/catalog/-c-21_25.html
    cnn

    i talked to pskits and they have CORTECO kit
    many parts are not included , for example triangle plastics ( 30,1 ) and 2 bearings
    taking in consideration complicity of this job I dont want to start it w/o all parts
    Last edited by champaign777; 10-13-2012 at 10:28 PM. Reason: Automerged Doublepost

  12. #12
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    I haven't heard of this problem, I had to replace my pump, they lied to me and it was made in China, should have spent the extra $200 for the LUK one.

    What are the symptoms of a bad steering rack?
    My 528 is a German Tank..
    My 2008 Chihuahua is Blue deal with it
    Always teaching now getting paid for it.

  13. #13
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    Quote Originally Posted by Jason5driver View Post
    Ok, that makes sense...
    I did not know the prices for the parts you listed above...

    I wonder how hard it would be to take apart your existing rack...?
    Plus, if you are able to get your existing rack open, how long would the procedure take to replace ALL of list parts above...?

    Regardless,
    The rebuilding the steering rack yourself is something definitely to keep in mind IMO...!


    Thanks!
    Jason
    I plan to do a triple job one day
    oil pan gasket
    steering rack rebuild / steering column rebuild
    25MM OE sway bar

    Just remove steering rack is probably ~1-2H
    You can leave your tie rods connected to wheel carrier and disconnect only inner part from steering rack
    so you basically don't need to do alignment after repair ( really ? yaa )
    Repair steering rack is ~3-4H if you have all parts
    All parts i mentioned above are from EURO forum from people who did this job
    Where to get ALL parts in US is a $1000 question
    Last edited by champaign777; 10-13-2012 at 10:29 PM.

  14. #14
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    Quote Originally Posted by champaign777 View Post
    I talked to pskits and they have CORTECO kit; many parts are not included , for example triangle plastics (30,1 ) and 2 bearings. Taking in consideration complicity of this job I dont want to start it w/o all parts
    I understand but the PS Kit I posted above should be enough to do the rebuild.

    The 2 bearings never wear out, the are bathed in PS Fluid and only rotates abit here and there (unlike belt pulley bearings that psin like crazy all the time).

    Parts #30 and #1...I don't think you need them.

    ----------
    champaign777,

    Did you talk to these people? They seem the be the ZF Rebuilder in the US:
    http://zf-steering.us/aboutus.htm

    PSA Steering Systems
    1961 4th Ave SW
    Bessemer, Alabama 35022
    Phone 205-426-4327
    Toll Free 800-915-4327
    Last edited by cnn; 10-14-2012 at 12:39 AM. Reason: Automerged Doublepost

  15. #15
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    CNN

    from your thread :

    http://forums.rennlist.com/rennforum...94-post20.html

    That Rack seal kit is WAY more complete than what we get here, with the curved shaft alignment piece, as well as some other pieces,
    like the plastic shaft alignment piece that goes inside the metal bushing. That is NOT what we have available to use here.


    yes i have contacted Jeff Parkerfrom from zf-steering.us regarding rebuild parts , no answer yet
    Last edited by champaign777; 10-14-2012 at 04:29 AM.

  16. #16
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    I bought a replacement rack for my 528i and will be replacing it this winter. If at that time you're still looking, I'd be more than happy to open mine up and provide specs on the bearings. My guess is you can find replacements through Timken, SKF, Koyo, National etc.

    2003 M5 LSx l 6 Spd Manual l 4.10 LSD
    Build Thread
    The chassis must always be regarded as a means to an end and never as an end itself

  17. #17
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    Basic Questions

    I know very little about this subject. I have some very basic questions to ask.

    • Are there any aspects to the system that allow for adjustment? (strength of assistance, for example)
    • Is it impossible to change the gear ratio? (I would like to make the steering wheel slightly more sensitive).
    • Does the rack need repacking with grease as part of normal maintenance? (I have seen pics of people using bright yellow grease. What's that all about?)
    • The e39 outer tie-rods are heavy (I just bought a pair, they are made of steel). Has anyone tried using a different outer tie-rod? Looking at the low resolution thumbnails on some of the vendor sites, the F10 uses, for example, what appear to be aluminum tie-rods.




    Last edited by Graham E39 528i; 10-15-2012 at 02:51 PM.

  18. #18
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    Graham
    steering R&P is a heavy duty part
    the only adjustment I know is 17MM nut on the top which makes your steering more stiff

    Quote Originally Posted by Schitzo View Post
    I bought a replacement rack for my 528i and will be replacing it this winter. If at that time you're still looking, I'd be more than happy to open mine up and provide specs on the bearings. My guess is you can find replacements through Timken, SKF, Koyo, National etc.
    that can be great 530i share the same steering R&P as 528i
    Last edited by champaign777; 10-14-2012 at 08:04 PM. Reason: Automerged Doublepost

  19. #19
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    Quote Originally Posted by champaign777 View Post
    Graham
    steering R&P is a heavy duty part
    the only adjustment I know is 17MM nut on the top which makes your steering more stiff
    What do you mean? Does it reduce the power assistance?


  20. #20
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    I believe that altering the "assistance" would be done by changing the hydraulic pressure which would be done by altering the pressure relief valve in the pump.
    "The water was not fit to drink. To make it palatable, we had to add whisky. By dilligent effort, I learnt to like it." Sir Winston Churchill

  21. #21
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    Quote Originally Posted by e21Terry View Post
    I believe that altering the "assistance" would be done by changing the hydraulic pressure which would be done by altering the pressure relief valve in the pump.
    Interesting. The plot thickens......


  22. #22
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    bump

  23. #23
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    subscribed!
    mine need rebuild too and this thread is very informative.

    *(e46, but now try to get some idea what's inside the rack)
    Last edited by hke46; 11-07-2012 at 12:55 PM.

  24. #24
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    Jeff from US ZF finally provided the following information

    7852 633 048 COMPLETE SEAL KIT $38.14 6 WEEK LEAD TIME
    7852 033 155 SMALL SEAL KIT $12.64 6 WEEK LEAD TIME

    There is original BMW set from E36 which people used for E39

    32131094629 GASKET SET $74.99
    32131128693 MOUNTING KIT $8.45
    Last edited by champaign777; 12-06-2012 at 12:15 AM.

  25. #25
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    champaign777 and others,

    I just saw something interesting in the Volvo forum and I thought I would share.

    Most steering rack leaks occur at the outer O-ring/seal, thus fluid coming out of the protective boot ---> on the garage floor. It virtually never leaks at the pinion end.

    Of course the proper way is to remove the Steering Rack and rebuild it from scratch or pay big bucks for a quality Steering Rack. But removing the steering rack from any car is a pain in the rear, not to mention the number of labor hours involved!

    This Volvo person replaced ONLY the Outer O-rings/Seals using the rebuild kit ($47) without removing the Steering Rack from the car.

    http://volvospeed.com/vs_forum/topic...rack-leak-fix/


    So, we need someone in E39 to act as "guinea pig" and do this for forum i.e., replacing the Outer O-rings/Seals without removing the steering rack from the car.

    Comparing with the Volvo, the BMW E39 Steering Rack is in a better location because (the Volvo 850/S70 SR is behind the front axle while the BMW E39 SR is in front of the front axle). So this job should be easier on the BMW E39.

    Rebuild kits can be bought for $50.

    The PS Rebuild Kit does not have the protective boot, so you have to order separately for the boot and clamps. Here are the Volvo TRW Rack photos for reference:




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