[cowpen]

Yesterday, I started hearing a fairly loud "creaking" noise from the front end while I was driving around the yard. I jacked up the front and have isolated the noise to the steering, and more specifically the steering box. The creaking isn't in a certain spot in the rack travel, but seems to be sort of random where it starts and stops when I turn the wheel. It can creak on either end of the travel of the rack, or even in the middle. If I really work it back and forth it seems like it goes away for a couple of lock to lock cycles, but then comes back in a random location. It almost sounds / feels like it has no lubrication. Doesn't matter if EPS is on or off. Also, the noise seems to follow the movement of rack rather than the turning of the pinion.

I did a search of the site to see if anyone's had similar issues, but came up empty. This thing is practically brand new! :mad-new: Any ideas?

 

[Toxic-21]

Yesterday, I started hearing a fairly loud "creaking" noise from the front end while I was driving around the yard. I jacked up the front and have isolated the noise to the steering, and more specifically the steering box. The creaking isn't in a certain spot in the rack travel, but seems to be sort of random where it starts and stops when I turn the wheel. It can creak on either end of the travel of the rack, or even in the middle. If I really work it back and forth it seems like it goes away for a couple of lock to lock cycles, but then comes back in a random location. It almost sounds / feels like it has no lubrication. Doesn't matter if EPS is on or off. Also, the noise seems to follow the movement of rack rather than the turning of the pinion.

I did a search of the site to see if anyone's had similar issues, but came up empty. This thing is practically brand new! :mad-new: Any ideas?

Slide your inner tie rod boots back and look at your inner tie rod ball and socket, I bet they are dry, there is no grease fitting. You will either have to wipe it on or use a grease needle.
Also the rack itself could be dry and the nylon tensioner is making the noise.

 

[cowpen]

Thanks Greg. I was hoping you would weigh in. I'll check that joint... hope that's all it is. If it's the rack I'll need some help I think. Will report back what I find out.

 

[Toxic-21]

Thanks Greg. I was hoping you would weigh in. I'll check that joint... hope that's all it is. If it's the rack I'll need some help I think. Will report back what I find out.

I have replaced several of them, and had them apart, looking at how they are designed.
So I should be able to help.

The inner part of the boot is held on with zip ties, so make sure you have some handy to replace them with.

 

[cowpen]

I slid the boots back, and there was grease present. No sign of water intrusion. Outer ball joints are fine. The ball and socket joints at each end of the rack were OK. As I moved the steering with the boot slid back, I could feel the creaks coming from inside the steering box on the rack. I packed the rack rail with bearing grease and ran it in and out several times, and it definitely improved, but not totally cured. There's some lateral play in the rack/steering rod that doesn't seem quite right to me. I'm running down to the camp tomorrow, so we'll see how it goes with the extra grease.

 

[Toxic-21]

I slid the boots back, and there was grease present. No sign of water intrusion. Outer ball joints are fine. The ball and socket joints at each end of the rack were OK. As I moved the steering with the boot slid back, I could feel the creaks coming from inside the steering box on the rack. I packed the rack rail with bearing grease and ran it in and out several times, and it definitely improved, but not totally cured. There's some lateral play in the rack/steering rod that doesn't seem quite right to me. I'm running down to the camp tomorrow, so we'll see how it goes with the extra grease.

The noise may be coming from the pinion bearings and seal. There is nothing you can do about this that I am aware of, except put more grease inside, and hope it makes it there. I tried sourcing the parts a couple of years ago with no luck, may need to try again. The steering rack is sold by polaris in a complete Assy.

Side Note:
If you disassembled the steering rack it might change your ( generally speaking) driving style, IMO they are very flimsy, but do work as they are supposed to.
With all the people running larger tires, if they have seen an OEM rack and pinion disassembled, they would be aware of the accident that is waiting to happen.

The lateral play that you feel, is the rack itself flexing, the oem rack only uses one guide bushing ( older models used hardened steel, new ones are nylon, and the nylon usually works it's way out, you will find it on the inner tie rod some times) on the passenger side, there is not one one the driver side, I'm not sure why. The rack bushings on both sides would make the rack more stable in the housing, creating a more positive feel, and take some of the pressure off the pinion gear and bearings.

When you have time, try removing the lower steering shaft if you have EPS, and turn the pinion gear by hand, either using the lower steering shaft or some sort of protection for the pinion gear splines, using pliers or vice grips.