5KT steering rack removal

[RC Ringlien <rringlie@isd.net>]

Fellow listers:
  This is a removal procedure for the steering rack on Audi 5000 turbos
with auto trans. The turbos have a bit more wiring and electrical gizmos
in the way, i.e. wastegate, aux. cooling pump, etc. You need 13mm
wrenches for the side mounting bolts and the steering wheel
adapter(inside car),17 mm for vertical bolt on inner tie-rod bracket,
and 19mm for the 2 inner tie-rod bolts.  Rachet-wrenches in these sizes
are a big help.  Unless you don't mind a lot of scratches, wear a long
sleeve shirt.  Park car with full access to driver side door and remove
right wheel. 
 1.  Remove the hydraulic oil reservoir--if bottom hose won't come off,
merely tie the tank towards the front of car the best you can.
 2.  On turbos, remove nut that holds wastegate solenoid to firewall and
tie it and other wiring out of way.
 3.  Remove the windshield washer fluid tank from holder. Rest tank over
top of firewall onto the black heater/AC cover.
 4.  Even though it's tight, remove hydraulic hoses from the sector
before removing side mounting or tie-rod bolts--everything remains solid
while working on these banjo bolts. The high pressure hose from pump
comes off first.
 5.  Laying in the most comfortable position possible(there are none),
remove steering column adapter from sector. Also remove large rubber
grommet from firewall.
 6.  Remove inner tie-rod bolts and bracket from rack.  
 7.  Remove mounting bolts from both ends of rack.
 8.  Pry right(passenger)side of rack out of bracket while also getting
sector shaft out firewall hole. Accelerator cable must be eased around
sector area of rack. The elec. cable near right end must be persuaded to
slip around rack towards firewall. A 1" flat chisel works to pry cable
around end.
 9.  Round up an assistant for final removal. Remove rubber flap from
opening. If alone, tie a magazine around right end with half of mag
poking through the opening--this helps to get rack end over lip while
you are leaning over fender lifting it through. Jiggle and wiggle the
best you can.  The sector shaft is the toughest part to finally clear
the hole. 

I hope this adds to info already in the archives.  Good luck.
Bob Ringlien
85 5kt
89 200
other generic cars