Tom84

I used search to find problems similar to mine, but couldn't find any that were quite alike.

My car is a 2008 E61 520d automatic with a regular servotronic steering. I saw a position sensor on the steering rack, don't know if that's stock on all E60's or if it's there because of the adaptive headlights.

When making small turning movements to the left, at very low speeds or especially when stationary with the engine off, I hear a clunking noise coming from the front left of the car and feel it in my steering wheel too.
Yesterday I had the chance to put the car on a service pit so I could run a few tests.

- Clunking noise seems to be coming from the left side of the steering rack or from the place where the tie rod is attached.
- The noise is the loudest with the wheels centered and the engine off, but can be heard and felt with engine and assisted steering active and the wheels turned out, though it's far more subtle then.
- When holding the left tie rod, the clunk can be felt very clearly (on the right tie rod I don't feel anything)
- There's no play on the lower steering joint



In the video the wheels/steering wheel are centered and we're making small movements to the left, and after that a few to the right to show the difference.

I think that there are 2 possible causes. One is the dreaded faulty steering rack, the other is the left tie rod inner ball joint that's got too much slack.

Any suggestions on the cause of this noise?

pcy

I say it's inner tie rod. If I were you, I'd replace inner and outer tie-rods and see if the sound goes away. Otherwise, take the car to a axle/CV-joints specialist (if one exists where you are). They can do a better job of isolating the source of the noise. They deal with noises like that all the time.

Tom84

Ok, thanks for your reply!
Should I replace both sides when I'm at it, or doesn't a wornout left side indicate that the right side is on it's way out too in this case?

pcy

while it may not absolutely necessary to replace both sides,I recommend replacing both sides and get the alignment done.

AchtungE60

I had this issue before ended up being a ball joint or bushing. I don't remember. I replaced them all just because. I too thought it was the steering u-joints and I greased them up but it wasnt' from there.

Tom84

I replaced the driverside tie rod today, but to little effect. As the rack was exposed with the dust cover removed, I went on and did the same test I did in the first video but with the tie rod still disconnected from the axle.

clunking noise + slack

As you can hear the clunking noise is still there, and you can see the rack making a strange upward movement wich I don't believe to be normal. Please correct me if I'm wrong, because as things are now I'm looking at a steering rack replacement, which is either quite expensive, or a real pain in the ass to DIY

edit:
A quick youtube search about answered my "is this normal" question, a few other questions then:

- would you advise against buying a second hand steering rack if it's tested and working?

- How to determine with which type of steering my car is equipped? I don't have active steering, but how to distinguish between servotronic and regular power assisted steering. Do all E60 steering racks have a position sensor?

sorry for the newbie questions, but that's who I am when it comes to BMW and 5-series

rafasjaen

m is similar sound

Tom84

rafasjaen, your noise sounds more like something rubbing or grinding instead of something with too much slack moving around. It also seems that the noise isn't always there?
You don't happen to have a video of the noise with your engine turned off?


As for my problem: I just ordered a rebuilt steering rack for 560€, as my local BMW dealer asks 1700€ for a new one, no labor included. I intend to do the replacement myself next week, I'll take some pictures during that process.

rafasjaen

ok

Tom84

I solved the problem by replacing the entire steering rack.

It wasn't a fun job, but everything went quite well, no nasty surprises. I did the replacement in my garage with only 2 jacks, 4 axle supports, a torque wrench and basic tools. I only had to buy a few torx sockets which I didn't have in my set. I used my engine hoist to support the engine while the axle was removed, but you can also use an engine support that is placed across your engine bay.

The fact that you have to lower the front axle is a little intimidating, but the engine bay (in my 2 litre diesel anyways) was designed in such a way that I could lower the front axle without having to release anything but the joint between the steering rack and the steering column.

If anyone who wants of needs to DIY the replacement of their steering rack can contact me if they have any questions.

I added a few pictures. I discovered that my sump was leaking oil in several places, at the seal and from the oil level sensor. So as you need to lower the front axle to be able to remove the sump, I made a virtue of necessity and replaced all those seals as well.