King James

Backing up a bit before the rant, I am finally getting around to addressing the problem I've had since first getting my Weissach of the steering wheel rubbing against the column/dash whenever I turn. I purchased upper steering shaft bearings (reading here on the list that it is a likely cause) and proceeded to open up my manual and get down to business.
The manual states that first you need to remove the Universal joint. Ok, seems simple enough, manual dictates that removing the 2 set screws should do the trick. While not easy, 20 minutes later, 2 set screws are out.

It is 3 hours later and I can't seem to find a way to get the steering shaft out of the U-Joint. While I take a break and let my knuckles bleed off a bit, I figured I would post to all the kind souls out there and see if anyone has gone down this road before and what words of wisdom / technique / butcher tools I seem to be missing?!?

My many thanks are in advance on this one!

Erik - Denmark

James,
I am wondering what you mean, but think you want to change the rubber bushes with poly bushes in the upper A-arm.
I yes, then you can remove the whole suspensions unit by loosen the lover (big) rubber bushes (easy),the upper three nuts on the spring/shock unit (easy), the lover bolts for the spring/shock unit (easy), The brake calibre (hang them up) (easy) and then the two nuts for the upper A-arm (damn difficult) - Voila
But I have no experience by changing the rubber bushes with Poly-bushes, I repaired mine by removing the longitudinal play by placing a 4 mm x 25/60 Ø Poly washer at the back end - That's works perfect!
Hope this helps you
Regards from Erik in Denmark

T_MaX

Eric, I believe James is talking about the aluminum U-Joints that connects the end of the steering shaft to the "Rack-N-Pinion".

Sorry, James I don't have any BTDT word of wisdom.

I would try some spray-lub and drive a wedge (large screw driver or chisel)into the slit end your tying to get off.

Normy

I did this when I changed my rack/mounts earlier this year.

I used a screwdriver in the slot to "pry" the clamps open as much as possible, then by contorting myself, I managed to get the connection apart by gentle persuasion with a hammer. Penetrating oil helped too.

The hard part was not getting them apart; the hard part was putting it all back together. Getting the clamp portion to line up with the splined shaft is a major pain in the rear!

Good luck-

Normy!
'85 S2 5 Speed

GlenL

Oh, baby. Bad memories flooding back.

I spent hours abusing my U-joint before I got it off. Had to screw a big sheet metal screw into the crack to get it open and a pickle fork to get it off. I was replacing the rack so some damage was acceptable. The U-joint is aluminum and the shaft is iron and the electro-welding was strong.

Erik - Denmark

T_Max,
Yes, you are right! (I think I am slipy, I went up at 4 AM this morning and drove in my 928 160 miles for a meeting in Copenhagen at 07.30 AM)
James,
This universal joint can be a pain to remove - Follow Normy's advise and use a plastic hammer or a normal hammer and a piece of hard wood -
As Normy said even more difficult to install - Remember to mark the position before you remove the joint and clean carefully before mounting.
Good luck!
Regards from Erik in Denmark

Eric G

When I replaced my steering rack, I got a tamp and chisel set from Sears (the chisels are hardened steel with a blunt tip - not for wood). One of the chisels fit perfectly in the slot on the U-joint, but it still took many hard blows with a mallet to get it loose. I also used lots of Liquid Wrench, too.

On a good note, I didn't have any problem getting it back together.

Good luck!

King James

Thanks to everyone for the advice and support. I spent a few hours under the ride last night and was able to free the steering shaft splines from the aluminum U-Joint, but I am unable to remove the shaft?!? The procedure is not spelled out in the manual, I have been trying to pull the shaft (from where the steering wheel is bolted on, but have been meeting resistance with about an inch of shaft left in the U-Joint, perhaps hitting the upper u-joint on the firewall? My question at this point is...how in the @%^#* do I get the U-joint off once the steering shaft is loose? I'm guessing I'm missing something easy, but for the life of me I can't figure it out!

Thanks again!

Erik - Denmark

James,
Did you loosen the steering rack?
If not, you cannot get enough space between the two shaft ends to get the universal joint out