Recently I had to replace the steering rack on one of the 2Gs I am currently working on. Since it needed much work and the owner was interested in a manual rack I decided to try and solve the 2G manual rack dilemma. I wanted to come up with a comparable solution.
My first step was to get together with a rack and pinion re-manufacturing specialist to see what we could come up with. The most common solution for many people is to simply loop the lines. This however creates a few problems which include too much play in the steering due to the power assist, torsion bars and rotary valve.
After some brain storming we came up with a much better solution that does not involve looping of the lines. The play in the steering is no longer there, there is no more fluid in the rack and it makes it much easier to turn without causing damage such as with the looping of the lines.
Part of the modification includes:
* Full disassembly, cleaning and inspection of the steering rack.
* A few key modifications done to the torsion bars and rotary valve.
* Using grease instead of fluid
The outcome of this project is a functioning 2G manual rack that has no play in the steering, no power steering lines, is easy to turn and does not have leaks due to power steering fluid. This is a long term solution that will provide a better driving experience
then looping the lines.
The pictures below are the outcome of what was done to a rusty, durty, greasy, blown rack.
My first step was to get together with a rack and pinion re-manufacturing specialist to see what we could come up with. The most common solution for many people is to simply loop the lines. This however creates a few problems which include too much play in the steering due to the power assist, torsion bars and rotary valve.
After some brain storming we came up with a much better solution that does not involve looping of the lines. The play in the steering is no longer there, there is no more fluid in the rack and it makes it much easier to turn without causing damage such as with the looping of the lines.
Part of the modification includes:
* Full disassembly, cleaning and inspection of the steering rack.
* A few key modifications done to the torsion bars and rotary valve.
* Using grease instead of fluid
The outcome of this project is a functioning 2G manual rack that has no play in the steering, no power steering lines, is easy to turn and does not have leaks due to power steering fluid. This is a long term solution that will provide a better driving experience
then looping the lines.
The pictures below are the outcome of what was done to a rusty, durty, greasy, blown rack.
