Rack woes, R & R

[Mike Arman <armanmik@n-jcenter.com>]

>
>Date: Thu, 18 Jun 1998 22:35:09 EDT
>From: AllradAudi@aol.com
>Subject: Steering rack work sequence??? 865ktq HELP!!!
>
>I have a rebuild kit for my 86 5ktq (It has been very unfriendly to the EPA
>lately) .. as well as my wallet at $15 a quart of fluid.... ANYWAY the Benley
>manual does not really spell out the way to take this thing out of the
car....
>Does the colum have to come out? how does it slide out? ... Are there
>shortcuts?   anybody ever rebuid one?  P.S.   I need a bomb too (cheap)....
>Anybody BTDT?????????
>
>Allrad....
>

Suggest you not rebuild the rack you have - it is a fairly significant pain
in the *** to remove and replace, and you'll get to do it again if there's
anything wrong with your rebuild. Get a lifetime warranty replacement from
Jorgen for $160.

This is the GREATLY abbreviated version - it takes about four hours the
first time, and having a helper makes life much easier. (this is from
memory, so may not be complete)

Have a Haynes or Bentley on hand!

Jack up front of car so front wheels can be removed, remove wheels, unsnap
rubber-fabric boots around right tie rod, and remove boot. Remove washer
reservoir. Stand on head inside car and remove lower steering column
coupling. Remove inner tie rod bolts, move tie rods out of your way. Don't
drop any bits into the mud! Remove hoses - you can get at one end of the
return (I think) hose with the rack still on the car, the other hose end is
inaccessable, so remove it at the pump end, leaving it on the rack. Remove
two bolts on left and one on right end of rack, rack is now loose.

Rotate rack slightly and wiggle it around - it comes out through the right
wheel well, out through the tie-rod hole. Really, it does, although it
usually takes some cussing.

Clean everything, transfer hose to new rack - note orientation! (new crush
washers, too, please - you can't get to this once it is back in the car!)
Insert new rack with hose attached back through wheel well hole. Helper
supports left side while you wiggle and cuss. Don't lay across top of
radiator - you'll break the outlet spigot (don't ask!)!

Torque everything to specs. Move into car: Helper presses steering wheel
toward front of car to correct clearance from housing (1/8"?), while you
lay on your back and drive lower steering column coupling fully home,
tighten bolt. Untangle yourselves, clean up.

Fill with Pentosin, bleed system, check level. Great fun.

Best Regards,

Mike Arman