redpathtribe

Trying to finish up installation of a rebuilt steering rack in my GT and I'm having difficulty getting the universal joint to slide back on the splined shaft of the steering gear. I've been using directions from John Pirtle's "guide", everything going OK so far, until this point.

I only took off the u-joint at the rack/steering gear itself. The rack is reinstalled/bolted up, pressure lines back on, but I can't get the u-joint to "slide" on the splined shaft. It's started on, but doesn't seem to want to go any further without some "persuasion"... I've been trying to pry apart the u-joint some at the slot, maybe not enough yet?

Any tips??? Did I need to take the u-joint off the upper shaft too? Should I have tried to slide the u-joint on before I bolted the rack in? BTW, doing this by myself... having a GREAT time...

Thanks in advance for any advice.

SeanR

Is the bolt that holds it together completely removed?

928worldwide

Make sure the notch in the stub on the steering rack is lined up with the bolt hole on the universal. Wiggle it back and forth while you try to push it on. Sometime I use a pry bar to push it on. I don't know an easier way if there is one. just work at it..... get some leverage without busting anything.

redpathtribe

Sean, yes the bolt is completely out.

I've been trying the wiggling, leverage, a little grease, a little "tapping" as my wife turns the steering wheel a little at a time...

I'm putting it back on the way it came off, i.e. rack centered, steering wheel centered. This is somewhat secondary, but does the bolt hole have to line up with the notch? It looks like it will slide through no matter what and then just clamp down on the splines holding it in place.

928worldwide

Yes it does look that way, but everytime I have trouble with that, I line the hole in the universal with the groove in the stub and voila.

redpathtribe

To do that, I would have to remove the u-joint from the upper shaft too. The rack is centered, so the splined shaft is where it is. I would need to remove the u-joint from the upper shaft, line the u-joint up with the notch and install it, then install the u-joint on the upper shaft with the steering wheel straight. Does the upper shaft have a similar notch too that I'd be up against? If it does, then something's way off... maybe my steering wheel.

928worldwide

before you do that, turn the wheel to get it where were talking about and see if that helps get the thing on. You can always adjust toe or move the wheel once it's done. This is a bitch job, I feel your pain You can pry the universal open some too, it takes a ton of brawn though....and don't booger the splines.

Landseer

I found it possible to turn the wheel to a position where the Ujoint has a better angle. You turn the rack also. You can eyeball the bolt hole and the slot in the rack and if you have enough light in the right places you can get it on without being a single tooth off.

So, when the Ujoint goes onto the rack, the rack is not at its center point, but neither is the Ujoint.

I've found a few tools that can be passed across or through the Ujoint, with the far end against the car to pry, and the close end able to be tapped by the side of a hammer, and other such means to persuade it on.

Critical of course to be sure no splines are messed up before you start. We've had to use a jewlers file to clean them up occasionally. A stubby wire brush for cleaning copper pipe fittings works to clean crap out.

Landseer

Basically, I guess I just said the exact same thing that Mason did. Congratulations, BTW, Mason, on your family news!

928worldwide

I guess it's good to mention that both ends M and F should be very clean of grease and dirt.

928worldwide

Awww. Thanks Chris. Kind of you.

redpathtribe

Mason, Chris, Thanks for the feedback.

Mason, how about a little (very little) grease to help it slide back on?

Chris, I may try what you've said, but I think it will leave my steering wheel way of. I'm trying to install it the way it came off. Last one to take the rack off was an extremely competent, highly regarded 928 mechanic when he rebuilt the motor. I would think it should go back on the way it came off, never seems to be that easy though.

When you guys have done this before, did you have the rack bolted up when you slid the u-joint on, or did you bolt the rack up first, then slide the u-joint on?

redpathtribe

Oh, and BTW too Mason, Congratulations on the new addition. Another new adventure starting up!

928worldwide

Time to grow up overnight I guess. I'm 28 and have always been living on the edge, wide open, max x, pushed to the limit of every possible rule..... this is the final nail in my wild coffin.......... I am alas, headed for fatherhood. Hopefully it's a boy so I can teach him all my bad habits

Seriously, thanks! Very kind of you.

Back to your problem, little grease no prob, so long as no dirt. and I always bolt up the rack and lines before the knuckly. Just wiggle twist, pry, and push, don't be afraid to move the actual tire to move the rack while your wiggling. Adjust alignment later. That's how I always did it. Right or Wrong dunno, but it worked.

Landseer

I've done it with rack on and off. Its awkward with it off. Not sure how Sean is doing it, but I think he is usually using a lift. Mine are on jackstands, different look.

With it on, you must turn the Ujoint and the rack in order to get enough the needed motion. Really, you can eyeball it and not miss a tooth. I've never missed.