odonnell

There should be two bearings- the one you see once you remove the black plastic cup (the splined shaft that the IMS mates to) and there is a smaller internal bearing I believe. Forgive me if I'm wrong, I never successfully got mine out either, and am going off of what I have heard/read.

I read a writeup for taking apart a 924 rack, found here. I believe it's generally the same process for a 944 rack. The smaller needle bearing needs to be driven out. Let us know!

A DIY thread with pics would go a long way, I know a lot of us would like to refurbish our manual racks.

bonus12

Hey guys, thanks for the continuing help. Today I still could not find a way to get the long notched shaft out, nor could I remove the short skrew-type shaft with splines. The bearing on the short shaft seems like it should be removed, but I can't see how!

I have much of the grease removed. I am hardly satisfied, but I might just have to resign to filling the thing with grease as is. The grease in there is very dark grey, completely opaque, and i cant get it all out as is. I have some red moly grease that i may use. Can I be fairly sure it had moly grease in it to start? Is it bad to mix them?


Maybe I can post pics tomorrow morning and try again.
Thanks.

Van

I assume you mean the pinion shaft? The one that connects to the steering wheel? Once the cover plate is off (with 3 screws, I believe), you may need a slide hammer to pull shaft, with that bearing, out.

bonus12

Yes, the pinion shaft. Thanks.

So a slide hammer connects to the shaft and pulls it out bit by bit? Any alternative to this tool? Would I be able to bite a vice grip on it (with padding of course) and bang it out like that? How does the pinion shaft come out when its spiral teeth are locked in the notched bore?

Thanks

supes6

To remove the pinion shaft, leave the small bearing on the bottom alone and re-install the intermediate shaft. IIRC you need to turn it all the way counter-clockwise until it maxes out, then keep turning and the pinion will be forced out the top.

With that said, the only bearing you can replace is the small cup bearing on the bottom - the inner race of the top bearing is part of the pinion shaft and not removable.

bonus12

Thanks. Have you really tried to this?
I've read this somewhere before and I have tried turning the pinion by hand, but it seems like too much force is needed, and by that I mean it has to be forced. Besides, how would you ever get the pinion back in? Not to mention, I don't think there is room in the box to have the pinion and notched slider separate. Maybe I am overlooking something? Of course, I have the rest of the parts removed, including the spring-loaded tensioner and tie rods. Thanks for all the help.

Van

I think I put the u-joint back on the pinion shaft and tapped upward with a hammer.

bonus12

Van, I can try that, but how does the pinion come out considering it is "threaded" into the notched slider shaft? Is the pinion supposed to rotate as it comes out?

supes6

Sorry to say but it sounds like you may be in a little over your head. Maybe take it to a machine shop or something and have them remove the pinion for you?

bonus12

It is my first time specifically rebuilding a Porsche manual rack. Not over my head by any means, just being careful. This forum is very useful and helpful. And figuring out this stuff is great fun.

Van

I'm not sure what you mean by "threaded" - the pinion has a helical gear to reduce backlash. It will just rotate a little bit as it comes up.

Winter44

Great thread. Keep us posted on your progress. I will be following the same process soon since I have a torn boot and am knee deep in the front suspension as it is.

bonus12

Success! It's OUT!

Thanks to everyone who helped. Van, I used your idea which was to attach the intermediate shaft to the pinion and tap it out with a hammer. I tapped in star pattern (think lug nus) so the bearing came out evenly. The bearing came out along with the pinion, but it took a bit more force than I expected. Then, the rack came out. I am very glad it's disassembled because I can properly clean and regrease.

Thanks again!! I will be happpy to make a write-up soon. Our 924-944-968 community is a great one.

Now, time for a big breakfast (more boisterously known as breakfast of champions).

Van

I'm glad you got it out... but that's too much information...

bonus12

Not what I meant! Hahah