200TQ-20V PS rack reseal kit.

Bernie Benz b.benz at charter.net
Tue Sep 13 17:24:34 EDT 2005

Hi Dave,

I've not seen the problem to which you allude on this nor on the earlier 5K
racks that I've done.  The piston rods have all been very tight in their
attachment to the rack.

Upon disassembly I've found that the new staked (not meant to be opened) two
piece rod seal housing houses the identical rod seal parts that are used in
the 5K racks, just different housings.  It's this primary sealing element
that is an inadequate design and should have been upgraded, IMO.

So, I can use my 5K sealing element redesign in this housing for its first
test.  My change is from the O-ring backed up hard plastic primary sealing
element to an elastomeric Quad ring with Nylon back up washer.  Quad ring to
prevent spiral failure and the back up washer to prevent extrusion of the
elastomer into the rod to housing clearance under these high pressures.

Wish me luck!


> From: "David Glubrecht" <daveglu at hotmail.com>
> The problem that I have seen on older 5k Audi racks (a long time ago I
> rebuilt a few) is that the piston rod is a pinched ball in a socket and
> usually this ball has slipped (I suspect from hitting a curb) and the
> rack/rod assembly is no longer true.  Unless this has been changed, I would
> start bychecking this alignment.
> Dave G
> ----- Original Message -----
> From: "Bernie Benz" <b.benz at charter.net>
> To: "SJM Autotechnik Sales" <sjmautosales at comcast.net>
> Cc: "200q20V mailing list" <200q20v at audifans.com>
> Sent: Monday, September 12, 2005 5:55 PM
> Subject: Re: 200TQ-20V PS rack reseal kit.
>> Your assumption is true, Scott.
>> Further research shows that Audi offers no rebuild kit for this rack, nor
>> does ZF.  ZF has the kits and/or parts therefrom exclusively for their
>> internal rack rebuild business, not even for resale to
>> independent rebuilders.   Thus, this 200Q-20V rack is only available
>> rebuilt
>> by ZF!
>> The only part of interest (to me, because it is the only failure mode of
>> this rack) in such a kit is the high pressure rod seal, the design of
>> which
>> is no better than that of the old 5K seal, just mechanically different.
>> So,
>> I'm forced to design my own, to redesign the old one.  Will do, and be
>> back
>> on the road soon.
>> Thanks for your effort,
>> Bernie
>> From: SJM Autotechnik Sales <sjmautosales at comcast.net>
>> Date: Mon, 12 Sep 2005 17:28:34 -0700
>> To: Bernie Benz <b.benz at charter.net>
>> Subject: Re: 200TQ-20V PS rack reseal kit.
>> Bernie,
>> I assume this 443 498 020B kit from Lemforder, is the older  5K kit? and
>> not
>> the one you need?
>> At 11:21 AM 9/11/2005, you wrote:
>> Hi Scott,
>> I finely got tired of the weeping rack and pulled it, a PITA Squared job.
>> BTDT on 5Ks before, so I assumed that it would be the same rack. Similar
>> but no, a later redesign.  Among other detail changes, the high pressure
>> piston rod seal has been changed, (not improved IMO, just changed) thus my
>> spare redesigned 5K seal will not fit.  Nor will the old 5K reseal kit be
>> any good for supplying the correct rod seal for this rack.
>> This rack is an Audi 443 422 065M,  ZF 7847 955 232.  Serial #472207,
>> 08/90.
>> Do you have a reseal kit for this rack?
>> If your X reference shows the same rack rebuild kit for this and the 5K,
>> not
>> right.  Please dig deeper.
>> Bernie
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