S40: Steering gaiter replacement

[PeterJC]

Hi
Can anyone enlighten me on how to change a damaged steering rack gaiter on a 1997 S40 2 litre CD (drivers side). There is very little room between the gaiter and a heat shield and a whole host of other bits. The Haynes manual unhelpfully says release retaking clips and remove gaiter. The gaiter is the original and even if I could get to it the clip looks pretty trick and is marked “G35Q” - is a special tool required and is it reusable? I have attached a couple of pictures for information.

[Clan]

Originally Posted by PeterJC

Hi
Can anyone enlighten me on how to change a damaged steering rack gaiter on a 1997 S40 2 litre CD (drivers side). There is very little room between the gaiter and a heat shield and a whole host of other bits. The Haynes manual unhelpfully says release retaking clips and remove gaiter. The gaiter is the original and even if I could get to it the clip looks pretty trick and is marked “G35Q” - is a special tool required and is it reusable? I have attached a couple of pictures for information.

not the nicest job at all , you need to take the heat shield off , it helps a bit , cut off the plastic clips , what type of clips come with the new gaiter ?

[aldred309uk]

I did the passenger side on my 1.9d the other month. I used cable ties for each end of the gaiter. Best tip I can give is to get a paint marker and draw a line along the inner steering rod, over the bolt and onto the tie rod end. This is to get the tracking back as close as possible. Back off the nut then count how many rotations as you remove the tie rod. You may have planned to do this already but just want to help.

[PeterJC]

Originally Posted by Clan

not the nicest job at all , you need to take the heat shield off , it helps a bit , cut off the plastic clips , what type of clips come with the new gaiter ?

Thanks for the responses. The new gaiter has plastic cable ties but the original clips are metal not plastic so won’t be easily cut off (see pictures). Is it possible to get the heat shield off and change the gaiter without taking off the exhaust, dropping the engine etc?
I suspect the existing gaiter was damaged around the clip last year when I had the tyres changed and the tracking done and it may be possible to fit a new clip / cable tie around the damaged end as it has pulled away where the clip grips but I’m not sure if this will work or what the local MOT garage will make of such a bodge.

[pierremcalpine]

Originally Posted by PeterJC

Hi
Can anyone enlighten me on how to change a damaged steering rack gaiter on a 1997 S40 2 litre CD (drivers side). There is very little room between the gaiter and a heat shield and a whole host of other bits. The Haynes manual unhelpfully says release retaking clips and remove gaiter. The gaiter is the original and even if I could get to it the clip looks pretty trick and is marked “G35Q” - is a special tool required and is it reusable? I have attached a couple of pictures for information.

Having now done this job twice I can tell you that it requires some patience. I have also found that it helps if you heat the gater in hot water for a few min before attempting to install. I also found that having some picks on hand (particularly the 90deg one) helps lift the lip of the gater over the rack. You do need to take that shield off. I’ve had better success working from the top but I’ve also found it really helps to have a second person applying steady inward pressure from the wheel well area as you lose your mind carefully lifting the rubber on all the way around. I also seem to remember having some success rotating the gater while keeping the pick carefully inserted in a way that encouraged the rubber to latch on.

[Clan]

Originally Posted by pierremcalpine

Having now done this job twice I can tell you that it requires some patience. I have also found that it helps if you heat the gater in hot water for a few min before attempting to install. I also found that having some picks on hand (particularly the 90deg one) helps lift the lip of the gater over the rack. You do need to take that shield off. I’ve had better success working from the top but I’ve also found it really helps to have a second person applying steady inward pressure from the wheel well area as you lose your mind carefully lifting the rubber on all the way around. I also seem to remember having some success rotating the gater while keeping the pick carefully inserted in a way that encouraged the rubber to latch on.

exactly right , that's the way I worked out the best way to fit one .

[mrfixer]

Just finished doing mine on Saturday morning biggest problem was getting the heat shield out of the way,easy enough once I had that moved to the side didn't need to remove it completely just forced it in towards the middle of the car so just enough room to work cleaning up the rack and replaced the boot

[PeterJC]

Thanks for all the advice provided. I understand I need to remove the heat shield and that should give enough room to replace the gaiter without further disassembly. I assume the existing original metal gaiter clip is levered off and I’ll have a go during the week and let you know how it goes.

[teddy326]

Can anyone clarify for me please.
I see 2 heat shields. One on the firewall which will come off with 3 off 10mm nuts.
One over the rack which obscures the clip for the gaiter on one side.
Is this rack heatshield just clipped on like the 850 pic I found on swedespeed?

Photos of 2001 S40 from top in cloud here:
https://app.box.com/s/a90acu3nmevwq3hvnoccx4am3jrglfa3
Photo 370 shows the lower heatshield obscuring the gaiter clip with one of the pop rivets and the edge of the upper heatshield.

850rackheatshield shows 2 push on clips.
Suggestion is that heatshield is essential to protect rack end seal from heat.

I want to replace the gaiter/boot on the side obscured by the rack heatshield.
It appears to be made of fibreboard or FG with Al Foil stuck on it.
There appears to be some pop rivets holding it on to something.
Have I got to break it to get it off and replace with some Alloy sheet clipped on?