gregeast

Does anyone have any tips or tricks to remove (and then re-attach) the intermediate shaft to the rack?

I've done it 2 or 3 times and it has been a bear each time. The fit if very tight, the universal joint on the end of the shaft makes it hard to get any leverage on it and of course there's almost no room to work in there.

Any and all insights are most welcome!

Greg

Maciek

Greg,
I had a terrible time reattaching the rack to the steering shaft. I ended up having to screw in about 3 screws into the female connector on the steering shaft to try and widen it as much as possible to be able to slide the rack in fully. I suggest lots of PB blaster/WD40. They key is to get the angle right, but sometimes thats not enough so try and widen the femail connnector as much as possible. Also, I tied some string to the steering shaft so that when I dropped it it was easy to pull back to where I needed it. Good luck.

austin944

For separation I stuck a large screwdriver in between the joint and the rack and pried it off. I believe I also had the rack lying loose and not completely bolted in so the joint would be easier to push off.

For installation I had a long socket extension dropped in from above with the head of the extension lying on the edge of the universal joint, and gently tapped it in with a plastic hammer. Also lubed the splines with plenty of anti-seize (or grease).

Matt H

I use the longest pry bar I have to loosen and like Austin, leave the rack loose. When reattaching I usually just curse at it
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gregeast

Matt - How do you use the pry bar? To wedge the collar open? To get underneath it?

GlenL

Big sheetmetal screw into the slit of the U-joint and a ball-joint separator.

Also, the rack must be free to move: you don't pull the U-joint off the rack, you push the rack away from the U-joint.

gregeast

Sheetmetal screw vertically into the slit or horizontally (perpendicular to the side)?

GlenL

From the side, towards the shaft.

The DareDevil

Yes, leave the rack loose while installing the shaft and you shouldn't have any problems. I didn't need to pry anything when sliding the shaft in; you just need to make sure it goes in straight.

Matt H

To wedge the collar open. I have never had much luck getting underneath of it.
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aribop

I just use a chisel to keep the collar seperated. Just drive it in enough to get clearance and leave it. It can be removed by hand afterward.

Matt H

Same principal, I just use the other because it is longer and I can hammer on it above the hoodline!
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gregeast

Thanks for all the good ideas guys. Last time I did this I was so frustrated I was starting to think that some sort of explosive might be in order, these ideas will be much tidier