chamilka

I am in the process of reinstalling a steering rack (1988 928). No problem sliding back on the splined shaft into the U-Joint. However, I do have hard time inserting the Bolt through the U-joint hole. When looking through the Bolt hole, I can see small amount of the Splined shaft protruding into the hole cavity hence not able to push the bolt through.
Is there a trick to this?
Thanks all

chamilka

below is a generic picture of the bolt hole I am referring to.

chamilka

All,
Is there notch of some sort in the shaft to give enough clearance? may be I failed to see that before installing it?

Rob Edwards

Yes, there is a notch. You have to get the splines on the U-joint aligned so that the 'flat' on the top surface of the U-joint (in your picture) is parallel to the axis of the bolt hole. You also need to get the shaft inserted far enough (but not too far) onto the shaft so the flat recess lines up in the hole in the U-joint.

Oldewoodupes

There is definitely a notch, so the bolt can only go through in one spot. Pry the clamp apart with a large flat screw driver, put it on the rack shaft as far as you can with your hand and then gently tap it the rest of the way with a hammer till the bolt hole and notch line up.

Mrmerlin

Based on what you're reporting you need to remove the rag joint off the rack then turn it one or two splines and then insert it again
the bolt should pass through the hole easily
this will also capture the rag joint to the spline shaft of the rack
if the bolt will not pass through then you have misaligned the rag joint to the flat spot in the rack

chamilka

thanks all. I will try tomorrow.

merchauser

this is a real PITA! with some patience, you will get it, don't despair. good luck