just finished steering rack

[dennis1987]

just finished putting a new steering rack on my URS4 i changed the gaiter and the track rod ends aswell, all i can say is that it is one of the most difficult and emotional jobs i have ever done how the car has survived the operation without a dent from my boots is beyond me, if there is anyone else wanting to attemp it, my advice dont pay a garage to do it, when i get around to it i will try and write up a how to, oif i can reme,ber all of the steps

[s2_bo]

Bloody good effort to do that with the engine in!!

[dennis1987]

right pig just managed to get it out through the drivers side wheel arch after taking half of the pipes off

[s2driveruk]

full credit doing it in situ...i changed the belows on my 3b and i skinned every knuckle and had to create some tools to reach various bits, was a monumental flippin nightmare

[dennis1987]

Guide for changing the steering rack on a URS4/UR6

This is the easiest way I found to do it (the only time ive done it so if anyone has an easier way just add it to the bottom)

1) Jack the car up and put it on axle stands take off the two front wheels. Free off the track rod ends from the steering arms and take of the gaiter on the inside of the drivers side wheel arch as this is where the rack is going to be coming out.

2) Turn the steering all the wau to the right so that you can get to the centre two bolts that hold the steering arms on, these two bolts are a held tight by the centre bracket being folded over to stop the bolts undoing (or at least they were on mine) if you are carefull about how you go about freeing them off you can re-use the bracket and not buy another one. you also need to unbolt the steering damper from the top of the bracket. Mind your knuckels on this one

3) Go inside the car and remove the tray underneath the steering wheel and then remove the air vent pipework, this gives you access to the steering column at the very base where it goes through the bulkhead is a clamp release the nut and bolt so that you can slide the rack out after unbolting it (I had to hit the old rack with a hammer and chisel to seperate the two so be prepared)

4) Back into the engine bay the passenger side of the steering rack is held in place by a single nut and bolt going through the rack and a bracket, this nut and bolt needs to come out completely and remember where you put it to save embarisment and swearing later. On the drivers side of the steering rack there are two bolts that hold it to the side of the engine bay, these two bolts on mine seemed to have welded themselves to the steering rack as i sheered them trying to get them off (watch your knuckles again) luckely i managed to pull the studs out by turning the bolts on the inside of the wheel arch.

5) Disconect the pipe that goes from the rack to the pump at the pump end and working along this pipe loosen off the bracket that holds it to steering rack as this makes it easier to get the rack out. With the rack unbolted you need to turn it towards the front of the car and unbolt the other end of the pipe you disconected from the pump from the rack.

6) With this pipe removed you should now be able to move the rack easier, first you need to move the rack towards the drivers side of the car to clear the bracket that was holding it on the passenger side, you then need to turn the rack so that the passenger side comes towards the fornt of the car and goes the other side of the loom that rans infront of it, this shoulld then allow you to pull it further across the passenger side. when you have done this you then need to squeeze the thick wire that runs infront of the rack around the drivers side end of rack, you then need to get the passenger side of the rack back into its holding bracket so you can then rotate the drivers side of the rack towards the front of the car so that it lines up with the hole in the drivers side wheel arch.

7) Turn the drivers side strut to the right so that it makes taking the rack out easier, it is also advisable to have the help of a mate to wriggle it out, but being carefull you can squeeze the rack out without snapping wires or disturbing pipework, this is fiddely so be carefull after this you should be left with a steering rack in your hands

8) To put the rack in is the reverse of taking it out obviously, but a word of advice when connecting the rack to the steering column I would advise using copper grease to help slidding it on and I also removed the clamp from the column to get it back onto the rack, this bit needs to be done with a bit of care as the splined shaft that comes from the rack is made of aluminium and strips easily and these teath are very small so be very careful

9) obviously i dont need to say to use new nylock nuts and seals for the pipes but get these things in advance to save time

if I have missed anything I do apologise but this should if I have get missed anything get you most of the way there
and most of all have plenty of cups of tea to hand

enjoy everyone