the only manual steering rack 'failure' I have seen is the bushings on the
outer ends can wear, so the end of the geared track  can move up/down up to
an eighth of  inch there, which translates to steering  play at the wheel.
 Other than that , I have never seen one seize, or strip out or anything
like that.
Quite a nicely made part I think - last forever if everything else is
maintained...
like shocks, alignment, and tire balance and roundness.

----- Original Message -----
From: "neil n" <musomuso@GMAIL.COM>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Friday, April 15, 2011 10:35 AM
Subject: Can a Manual Steering Rack Fail Internally?

> Hi all.
>
> Long story short, I suspect that my #1 steering rack was making a
> *minor* clunk sound. No play seen or felt, and no play at inner/outer
> ends of tie rod. I have a spare rack. Both are OEM (West Germany)
>
> I inspected each on the bench.
>
> #1 - where pinion rides, steering wheel centered, there's a *tiny*
> visible difference (wear?) on 2 or 3 rack teeth. Gears turn smoother
> and more easily than #2. Rack was always lubed by me and boots always
> ok.
>
> #2 -  feels "tighter" to turn, but is slightly easier to turn just L/R
> of center mark, wheel centered. Rack had a funny brown substance on
> it. (rust?)
>
> On both, what little I can see of pinion gear shows no visual wear
> marks and can't feel play between rack and body or pinion and rack.
> Each show almost identical wear marks on round part of rack at each
> end but feel smooth.
>
> Aside from play in the steering gear parts, what signs does a Vanagon
> manual steering rack give before it fails?
>
> Do they actually fail internally? Like are there cases where the rack
> suddenly fails?
>
> A  local offering of a new complete rack did not seem like a quality
> part. A Lemeford is pricey as heck. I know one can't put a price on
> these types of parts, but for now, just need to gain confidence in my
> steering rack so i can re install and use my Westy!    :)
>
> Neil.
>
> --
> Neil Nicholson '81 VanaJetta 2.0 "Jaco"
>
> http://tubaneil.googlepages.com/
>
> http://groups.google.com/group/vanagons-with-vw-inline-4-cylinder-gas-engines