XJ XJ6 / XJR6 ( X300 ) 1995-1997

Tips on Power Steering Overhaul

Old 01-27-2019, 03:58 AM
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Default Tips on Power Steering Overhaul

It has come time, to repair my poor situation regarding power steering. For those unfamiliar with my posts this xj6 sat outdoors for approximately 4 years, which apparently didn't do the rack seals any favors. The car also has currently 139k on the odo and is over 20 years old so these things happen.

My rack and pinion seal on the drivers side appears to be totally shot, as the boot has come off the outer end and the fluid comes out of it pretty heavily. Ive been dumping various stop leaks in because I was planning on this repair anyway come tax season, and figured if something worked before then....yay!... The leak is up to one gallon per week, varying by whether or not there's Lucas in the system.

It appears these stop leaks have had ill effects, maybe too much swelling of certain seals, as any time one of them has almost cured the problem, I start building pressure in the reservoir and it blows all of my fluid out for a few days, one product left me with no power steering at all for a couple days.

The car has been driven daily with this issue as any down time longer than a weekend would leave my family without transportation when I'm at work.

I have decided with the abuse and failures of the system to replace the pump and rack both. I sourced a 9/10 condition pump with a ZF reman tag affixed complete with the front bell piece and short metal line for $89 shipped. I also sourced a reman rack and pinion for $209 shipped on sale. It is without the sensor, So hopefully that is correct for a 96 x300 w/o traction control.

My main questions are :
"How do I correctly remove and install each the pump and rack, with basic tools ( no lift )?"

" Should I replace the rubber hoses all while doing this job, and what are the proper hoses to use?"

"Did I order the correct rack, and if not can I adapt it with parts from my failed unit?"

​​​​​​"Should I use regular power steering fluid or something else like atf after the repairs?"
Due to the volume of the leak I went through a few gallons of Lucas sure-shift I happened to have a bucket of on-hand because it was there.

And just in general any tips and suggestions for the job would be great!


Last edited by 96x300; 01-27-2019 at 04:47 AM. Reason: Corrections
Old 01-27-2019, 05:30 AM
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I haven't done the pump but the rack is straight forward.

Centre the steering Wheel before you start and try and lock it in position. Do not move the steering wheel while the rack is off (this can damage the clock spring for the Air Bag).

Make sure the new rack is centred also before fitting.

There are 4 easily accessed mounting bolts on the subframe which should not give any issues. The pipe unions may be tight but take your time and don't damage them. You should use a flare nut spanner on them to reduce the risk of damage.

The track rod ends - count the number of turns to get them off and use the same count to put back on the new rack. Get the tracking checked properly after the job is completed.

The knuckle for the steering column again should not present any issues.

Generally the hoses have a long life (the feed hose from the reservoir sometimes weeps). If you don't have any leaks from them then I'd just leave them alone. It's no big deal to change them as a separate job later if required.

The recommended fluid is Dexron III.

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Old 01-27-2019, 07:34 AM
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I never could cross reference the manufacture rack numbers of the 2 racks on the X300

One has the servo to dampen the steering at high speed with a attached servo

Hot sure this is the correct seal kit number

The rack manufacture is used on BMW's

See file attached
Attached Files
File Type: pdf
x300 zf with servo.pdf (1.07 MB, 11 views)

Last edited by Lady Penelope; 01-27-2019 at 08:13 AM.
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Old 01-27-2019, 03:30 PM
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Thank you for the quick replies! I may have trouble anchoring the steering wheel since mine doesn't lock, but I'll figure something out. I was thinking a ratchet strap wrapped around the bottom of the wheel and anchored somewhere under the seat should do the trick.

Here are the parts I ordered, the rack just has a generic image.

Old 01-29-2019, 02:37 AM
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Anyone know anything regarding changing the pump? Just trying to be prepared before the parts come in!
Old 02-03-2019, 08:48 PM
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Alright...well the pump was very simple. I have the wrong rack and pinion thoigh which is not servotronic. The lines appear to be different and my steering shaft is too short. Can I just get lines and a shaft from a non servotronic x300? And if anyone has these please message me and let me know what you need for them. My car is currently stranded in a friends garage until i fix this
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