Van

It's pretty simple... it's just a metal bar with gear teeth cut on one side. That adjustment it a bolt against a concave "button" that presses on the back side of that bar. If there's grit or even dust in there (is your rack centering plug in place?) it will act like sand paper between this button and the bar. Because most of your steering is done in the center of the rack gear, that part of the bar gets worn more. If you're getting tightness as you turn side to side, then that might be your problem.

Unless you get the whole rack bar reduced in diameter on a centerless grinder, your only other real option is to just get another steering rack.

arthropraxis

You probably already checked this, but it may be the steering rack bushings.

MAGK944

If I remember correctly when I refurbished mine, there is a spring in that rack that acts on something?? Could this cause an issue if it is worn/broken?

arthropraxis

Maybe, you have it too tight. Loosen up the bolt until it is sloppy off center. Have someone rock the wheel back and forth while you tighten it just enough to take the slack out. Worth a try.

Crackership

Not sure if you have a de-powered power rack, or an actual manual rack, but Rennbay has a good tutorial for rebuilding a PS rack with lots of taken-apart pics.

Also, I had a similar problem with my PS rack on my first 944 where the rack would stick badly when turning side to side. What caused it was one of the snap rings that holds the wiper bushing in place on the shaft broke, which allowed the wiper bushing to move and get wedged against the housing... An afternoon, a Rennbay seal kit, a pipe bushing and a pipe cap from Home Depot and a rod bearing from a Buick 455 later, the rack was all better.

Maybe that'll help?

Van

Dave, the manual rack doesn't have that bushing. (At least mine didn't...)

MAGK944

This article has some good info on rebuilding a manual rack. It's a VW but the components and layout look the same. He also does a Quaife Quick Rack upgrade at the same time. GL

http://www.hasengeeks.com/projects.p...=steering_rack

Crackership

I kinda figured a manual rack wouldn't have that bushing, just thought I'd throw it out there in case though...