tie-rod or maybe steering rack issue?

[ascendotuum]

About a week ago, I did some refreshing to the front steering/suspension since it was pretty sloppy. Here's what I replaced:

Sway bar endlinks (new oem)
Front control arm bushings (powerflex urethane)
Complete tie-rods inner and outer (new oem)

So yesterday, I took my car to my local shop to get an alignment done and to have them check the ball joints, since I didn't replace those and I wanted to make sure they were still OK. So the mechanic told me the ball joints are fine, but he can't do an alignment because the inner tie-rods are badly worn. When he moves the wheel there is tons of play inside the boot where the inner tie-rods are. I said that's weird because I just replaced them a week ago with brand new ones fresh out of the box..

Should I go somewhere else and get a second opinion? Or should I call ECSTuning and try to get them replaced? The tie-rods seemed in great condition when I put them on I don't see how they could be bad. The joints were very tight.. but I guess it's possible?

Or could it be the steering rack itself? I know I have a power steering fluid leak and I haven't checked the level in awhile so I'm pretty sure it's low on fluid. Could that cause this issue?

EDIT: Looks like it's the steering rack. http://www.youtube.com/watch?v=E8mmtrOgrz0

Thanks

[jlevie]

I can't see that being the rack. The rack shaft that each tie rod connects to is a single piece of metal.

If the motion truly is at the inner ball joint of a tie rod, the part is defective. Pull the boots and investigate.

[Northern]

Did you use (new) locking plates?

[ascendotuum]

Did you use (new) locking plates?

Actually, no. I re-used the old ones. They weren't mangled too bad so I just straightened them out and put them back on. Hammered them back in place as well, of course.

But I will be sure to order new ones this time.

[Wanganstyle]

Crawl under car and grab the inner tie rod; wiggle up and down with force. If the tie rod ends are tight and there is still play then the rack itself can be bad.

I've had a rack with sloppy internals and fitted new tie rod inner/outers; still drove sloppy.

Solution: toss the rack and replace with a newer better rack that does not have slop; or send it to a steering rack specialist and have it rebuilt.

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[ascendotuum]

Alright, I will try this when I get home. So if I pull back the rubber boot, I should be able to see if the play is in the inner ball joint or the rack itself.

I find it hard to believe that the brand new, still sealed in plastic tie-rods were defective. But at this point I kind of hope that they are. I don't want to have to replace the steering rack :(

[Wanganstyle]

Alright, I will try this when I get home. So if I pull back the rubber boot, I should be able to see if the play is in the inner ball joint or the rack itself.

I find it hard to believe that the brand new, still sealed in plastic tie-rods were defective. But at this point I kind of hope that they are. I don't want to have to replace the steering rack :(

It's pretty unlikely that both sides of new inner and outer tie rods are defective.

It's more likely that an 20 year + old rack could be worn

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[ascendotuum]

So I finally got around to diagnosing this issue. There isn't that much movement, but it's definitely not the ball joints. Do I have a bad steering rack? Also there is a lot of grease in there is that normal?

https://www.youtube.com/watch?v=E8mmtrOgrz0

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[Wanganstyle]

Time to change the rack itself; your tie rod looks quite new and the wiggle is from inside the rack

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[usualdeviant]

On a similar note, right around the same time you went to have your alignment, I went to have mine. They told me the same thing, there was play in my inner tie rod. I too, replaced those myself, some time ago. The problem with installing these things is that the adjusting nut planes that accept the wrench (32mm) are so thin, that you need to use, you guessed it, a THIN 32mm wrench in order to adjust them. I did not have one of those lying around at the time, so I probably just snugged them "tight enough" with channel locks, then secured the lock plates and called it a day. Well over time, one of them came loose.

Bavauto sells a nice tool for this job, disguised as a tool only suitable for adjusting the fan clutch nut and nothing else. But I tell you what, it works just as great on those inner tie rods. It's nice and chrome and shiny and it even says BMW on it. I recommend one of these to put on your wall if nothing else.

Anyway, after that, they were able to align it just fine. You may not be so lucky, but I was.

[ascendotuum]

I ended up using a big fat pair of vice grips. Clamped so tight they marred up the bolt part of the inner tie rod (you can see the marks in the video). But they are for sure tight as F***

Don't think I'm that lucky... but a Z3 steering rack will be an upgrade anyway so I'm not too bummed.

[usualdeviant]

I'm waiting till my E30 rack leaks faster to do that mod!