Fleet Case Study: How Rebuilt Steering Racks Transformed Reliability for Berlingo Van Fleet
Posted by SING SPARE PARTS CO on
Table Of Contents
- Introduction
- The Challenge: Recurring Steering System Failures
- Understanding Steering Rack Issues in Commercial Vans
- The Sing Spare Parts Solution
- Implementation Process
- Results and Benefits
- Customer Testimonial
- Conclusion
In the demanding world of commercial fleet operations, vehicle reliability isn't just about convenience—it's about business continuity. When a delivery service company operating a fleet of 25 Citroën Berlingo vans began experiencing recurring steering system failures, they faced rising maintenance costs and increasing vehicle downtime that threatened their service reliability.
This case study examines how Sing Spare Parts Co Pte Ltd, with over 50 years of experience in automotive parts reconditioning, provided a solution that not only addressed the immediate steering rack issues but also delivered long-term reliability improvements and significant cost savings.
Through the implementation of professionally rebuilt steering racks using Sing Spare Parts' proprietary SP3G reconditioning method, the fleet operator was able to transform their maintenance approach from reactive repairs to preventative quality enhancement—resulting in extended service intervals, improved driver satisfaction, and a substantial reduction in total ownership costs.
The Challenge: Recurring Steering System Failures
The fleet in question consisted of 25 Citroën Berlingo vans, primarily used for last-mile delivery services across Singapore. With each van covering approximately 80-100 kilometers daily in urban conditions, the fleet was experiencing an unusually high failure rate of steering systems, particularly in the rack and pinion assemblies.
Key issues reported by the fleet manager included:
- Inconsistent steering response reported by drivers
- Fluid leaks from steering rack seals
- Unusual noises during steering operation
- Excessive steering play developing after 18-24 months of service
- Increasing maintenance costs as vans aged
These issues led to significant operational challenges, including unplanned vehicle downtime, driver complaints about handling, and safety concerns. Most critically, the fleet manager was facing replacement costs of $900-1,200 per van for new OEM steering racks, with labor adding another $200-300 per installation.
Understanding Steering Rack Issues in Commercial Vans
Steering rack failures in commercial vehicles like the Berlingo van typically stem from several factors that are particularly relevant in Singapore's operating environment:
- Heat and humidity: Singapore's climate accelerates deterioration of rubber seals and boots that protect steering rack components
- Urban driving patterns: Frequent turning, parking, and maneuvering in tight spaces puts additional stress on steering components
- Load factors: Delivery vehicles often operate at varying load weights, creating inconsistent stresses on steering systems
- Road conditions: Navigating speed bumps, curbs, and occasional rough surfaces impacts steering component longevity
For the Berlingo vans, these factors combined with the vehicle's design characteristics created a particular vulnerability in the rack and pinion steering assembly. The fleet manager had previously attempted to address these issues through regular maintenance and replacement with new OEM parts, but found this approach to be both costly and disruptive to operations.
The Sing Spare Parts Solution
After consulting with the fleet manager to understand their specific challenges, Sing Spare Parts proposed a comprehensive solution centered around their rebuilt steering racks for Berlingo vans. The recommendation was based on:
1. A complete analysis of the failure patterns in the existing fleet
2. Evaluation of the specific Berlingo steering rack design and common wear points
3. Development of a reconditioning specification that addressed the identified weaknesses
Rather than simply replacing failed units, Sing Spare Parts recommended a proactive replacement program using their rebuilt steering racks that had been reconditioned using their proprietary SP3G method—a technique refined over five decades of automotive component reconditioning experience.
The SP3G Reconditioning Method
The SP3G method represents Sing Spare Parts' unique approach to component reconditioning that goes beyond simple repair to actually enhance the original component's performance characteristics. For the Berlingo steering racks, this process included:
- Complete disassembly of the steering rack unit
- Ultrasonic cleaning to remove all contaminants and old lubricants
- Precision inspection of all metal components including the rack teeth and pinion gear
- Precision machining to restore original specifications or enhance wear surfaces
- Replacement of all seals, bushings, and O-rings with high-temperature, climate-optimized components
- Application of proprietary surface treatments to reduce friction and increase durability
- Reassembly under clean-room conditions with specialized lubricants
- Comprehensive bench testing to verify operation under simulated load conditions
The key differentiator in the SP3G method is the application of proprietary surface treatments and lubricants specifically formulated for Singapore's climate conditions. These treatments address the primary failure points in the original design while optimizing performance for the specific operating conditions faced by the fleet.
Quality Control Process
Each rebuilt steering rack undergoes a rigorous quality control process before being approved for fleet installation:
- Initial inspection and hydraulic pressure testing
- Computerized simulation of steering loads and movements
- Measurement of steering torque consistency throughout the rack travel
- Verification of seal integrity under pressure extremes
- Extended durability cycling (equivalent to approximately 6 months of use)
This quality control process ensures that every steering rack not only meets but exceeds the original manufacturer specifications, providing confidence in the long-term reliability of the component.
Implementation Process
Rather than waiting for catastrophic failures, Sing Spare Parts worked with the fleet manager to develop a phased replacement schedule:
Phase 1: Immediate replacement of steering racks in vans showing early warning signs of failure (7 vehicles)
Phase 2: Scheduled replacement during regular maintenance intervals for vans with high mileage but no current issues (10 vehicles)
Phase 3: Proactive replacement of remaining units based on usage patterns and projected failure timeline (8 vehicles)
This approach minimized operational disruption while systematically upgrading the entire fleet. Each installation was performed by certified technicians familiar with the Berlingo's specific requirements, with a comprehensive post-installation inspection and road test to verify proper operation.
The rebuilt steering racks were supplied on an exchange basis, with the fleet's old units being returned to Sing Spare Parts for reconditioning. This exchange program provided additional cost benefits while ensuring a steady supply of components tailored to the fleet's specific needs.
Results and Benefits
Reliability Improvements
Over the 18 months following the implementation of the rebuilt steering rack program, the fleet experienced:
- Zero failures of the Sing Spare Parts rebuilt steering racks
- Elimination of driver complaints related to steering performance
- Reduction in related steering component issues (such as pump failures) by 60%
- More consistent handling characteristics, particularly when fully loaded
- Extended service intervals for steering system maintenance
These reliability improvements translated directly to operational benefits, with unplanned downtime due to steering issues reduced from an average of 3.2 days per vehicle per year to zero during the evaluation period.
Cost Analysis
The financial benefits of the program were substantial:
- Direct component cost savings: The rebuilt steering racks were provided at 60% of the cost of new OEM units, resulting in immediate savings of approximately $400-500 per vehicle
- Labor cost reduction: The preventative replacement program reduced emergency repair scenarios, cutting labor costs by approximately 25%
- Downtime cost avoidance: By eliminating unplanned downtime related to steering failures, the fleet avoided rental replacement costs and service disruptions estimated at $300 per day per vehicle
- Extended service life: The SP3G reconditioned steering racks demonstrated longer service life in the test group, projecting to a 40% increase in component lifespan
Over the full fleet of 25 vehicles, these savings amounted to approximately $21,000 in direct costs during the initial implementation, with ongoing annual savings projected at $12,000-15,000 through reduced maintenance and extended service intervals.
Environmental Impact
Beyond the operational and financial benefits, the reconditioning program also delivered environmental advantages:
- Resource conservation through reuse of major metal components
- Reduction in manufacturing energy requirements compared to new production
- Decreased transportation carbon footprint due to local reconditioning
- Proper handling and recycling of all replaced components and fluids
This environmental aspect aligned with the fleet operator's corporate sustainability initiatives, providing an additional benefit beyond the direct operational improvements.
Customer Testimonial
"After struggling with recurring steering rack failures in our Berlingo fleet, the rebuilt units from Sing Spare Parts have completely transformed our maintenance approach. Not only have we eliminated the unexpected breakdowns that were disrupting our delivery schedules, but we've also seen significant cost savings compared to using new OEM parts. The steering response is actually better than when the vans were new, and our drivers have noticed the improvement. The preventative replacement program has allowed us to schedule maintenance during off-peak hours, further reducing operational impact. I wouldn't hesitate to recommend their hydraulic power steering rack and pinion rebuilding services to any fleet manager facing similar challenges."
— Marcus Tan, Fleet Operations Manager
Conclusion
The success of this case study demonstrates the significant advantages of using professionally rebuilt steering racks for commercial van fleets operating in Singapore's unique conditions. By addressing the specific failure modes common to Berlingo vans and implementing Sing Spare Parts' proprietary SP3G reconditioning method, the fleet was able to achieve:
- Improved reliability and extended component lifespan
- Significant cost savings in both parts and operational expenses
- Enhanced driver satisfaction and safety
- Environmental benefits through component reuse and local reconditioning
The case underscores the value of working with experienced specialists like Sing Spare Parts Co Pte Ltd, who combine deep technical knowledge with innovative reconditioning techniques. For fleet operators facing similar challenges with steering systems or other critical components, this approach offers a compelling alternative to the traditional cycle of OEM replacement parts.
With over 50 years of experience reconditioning automotive components and a proven track record with commercial fleets, Sing Spare Parts continues to provide sustainable, cost-effective solutions that enhance vehicle reliability while reducing total ownership costs. Whether your fleet consists of delivery vans like the Berlingo or other commercial vehicles, the benefits of professionally rebuilt components are clear—particularly when those components are reconditioned using specialized techniques like the SP3G method that address the specific challenges of Singapore's operating environment.
The transformation achieved by implementing Sing Spare Parts' rebuilt steering racks across this Berlingo van fleet illustrates the substantial benefits available to fleet operators who move beyond simple part replacement to embrace quality reconditioning solutions. By addressing the underlying engineering challenges specific to these vehicles and Singapore's operating conditions, Sing Spare Parts was able to deliver improvements that exceeded the original component specifications—resulting in better reliability, lower costs, and enhanced driver satisfaction.
For fleet managers seeking to optimize maintenance budgets while improving vehicle reliability, this case study provides a clear roadmap: partner with specialists who understand both the technical aspects of component failure and the operational realities of fleet management. With their proprietary SP3G reconditioning method and five decades of experience, Sing Spare Parts Co Pte Ltd continues to lead in providing sustainable automotive solutions that deliver real value to commercial fleet operations.
Improve Your Fleet's Reliability with Sing Spare Parts
Are you facing similar steering system challenges with your commercial fleet? Sing Spare Parts offers comprehensive solutions for various vehicle models, including:
- Drive shaft reconditioning services
- Constant Velocity Joint repairs and replacements
- RHD Electric Power Steering Rack and Pinion rebuilding
- RHD Hydraulic Power Steering Rack and Pinion reconditioning
Contact our team today to discuss how our 50+ years of experience can help improve your fleet's reliability while reducing maintenance costs.
Visit: https://singspareparts.sg or call: +65 6745 7871