rebuilt rack is about 18 months old and very sloppy. Lots of clunking going on down there when going over potholes. Verified the rack is clunking by pulling off the boots and disconnecting the tie rods from the arm. Then illum the inner rack tube while moving the steering rod in and out. Seems to be a lot of play near the actual rack and pinion gear assembly. Removed the tension spring plug and spring to find the tension spring piston is froze in position. This I assume allows for the sloppy, loose contact between the rack gear and the pinion gear. First thought was that I didn't flush the system well enough when installing the new rack last year. But the P/S fluid filter is still good. So...is the rack possibly a bad overhaul, or did the tension spring piston plug some how find a little crud that I missed. Going pull it apart after Dinner and find out. Open to your ideas and comments.

Incidently, Does anyone know what the steel cylinder like appartus is that clamps onto the high pressure P/S line. Is it a vibration damper of some sort?

I figured that is what it is after first thinking one was a splice and the source of my leak. Kinda surprised to see more in the boneyard, but not on all, so I unwrapped the hose clamp.
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Art Benstein near Baltimore

Hey Art,
My first thought was that it was a splice for a leak. But then, when I took it aprt I got to thinking, no way. Only other solution I can come up with is a vibration dampner, but then- it's even kind of crude for a dampner. I dunno?

Only a comment-- it sounds to me like you took more care and precautions (filter) than what I expect is routine in most automotive reman facilities. No inside knowledge about that industry, just a few dozen years of observation. My wager is you'll find the original cause that rack became a core in the first place. Also bet if you had more 240s in boneyards up there you'd rather get a used than a reman. Useless commentary.

Looking at manual, cam rack shims leave .05 to .15mm free play while the ZF does this with washers for about the same (.1 to .15).
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Art Benstein near Baltimore