Replacing Steering Rack Boots on a Peugeot 205

Both steering rack boots (or bellows) on my Peugeot 205 were perished, allowing moisture and dirt ingress. If not corrected, this can lead to play in the steering. In the Netherlands the boots are checked as part of the yearly road worthiness test (MOT/APK). So let's get on the tools and fit two new ones!

Supplies

New steering boots: FEBI BILSTEIN part number 18027 (for my 1998 205 Generation without power steering)

Tools:

• Jack
• Axle stand
• Torque wrench
• Ball joint splitter
• 19 mm spanner
• 16/17/19 mm socket (depending on the size of nut on the ball joint)
• Sand paper
• Knife
• Bucket of hot water
• Optionally: grease
• If the steering ball joints are really tight: torch, big wrenches

Step 1: Remove Wheels

• Chock your wheels.
• Put on the handbrake.
• Loosen the wheel lugs.
• Jack up the car on the jack points.
• Secure the car with an axle stand.
• Remove wheel lugs.
• Remove wheel.
• Put wheel under the car, as extra safety.

Step 2: Remove the Steering Ball Joint

1. Slacken the jam nut a quarter turn.
2. Remove the ball joint nut. If the ball joint spins, put some pressure on it with e.g. a jack.
3. Use a ball joint splitter to loosen the tapered fit. If you don't have one, you can use two hammers. Hold one hammer as an anvil against the steering knuckle and hit the steering knuckle on the opposite side with the other hammer. Do not directly strike the ball joint!
4. Unthread the steering ball joint from the track rod. Count (and remember!) the number of turns needed to take it out. If you turn the exact same number when refitting, a wheel alignment is not necessary.
5. If the ball joint is in pretty tight, there may be some locking compound (e.g. LockTite) on it. Heat up the shaft where the ball joint is threaded into to release the locktite. Using two big gripping spanners, free up the ball joint.

Step 3: Remove the Old Steering Boot

1. Chances are the track rod is rusty. To aid in removal and refitting, clean it up with some sand paper. Especially when fitting the new boot; we don't want to tear it.
2. Pull off the old boot. It may turn inside out because it is stuck on the narrow part on the track rod. In that case use a knife to carefully cut the boot.

Step 4: Refit New Boot

1. Optionally: apply some grease on the steering joint.
2. Hold the new boot in hot water to make it pliable. You don't have to dip it in fully; we don't want to get moisture inside the boot.
3. Wrestle the boot over the track rod. Use your thumb to push the track rod through the narrow hole.
4. Seat the boot on the steering rack.
5. Secure with tie wraps.

Step 5: Refitting Is the Reverse of Removal

1. Refit the ball joint, turning it the same amount of turns as when you removed it.
2. Lock the ball joint jam nut.
3. Retighten the ball joint nut to 35 Nm. If the ball joint is spinning, put pressure against it with e.g. a jack.
4. Refit the wheel. Lug nuts should be torqued to 85 Nm.
5. Remove axle stand.
6. Lower car by removing the jack.