How To Guide - E36 Steering Rack Swap

[TrentW]

Speaking of knuckles...

Can't get the steering knuckle loose from the steering column shaft. It's been two 5-6 hour days soaking with PB Blaster, spreading the clamp end gap wide as possible, prybar between knuckle and firewall. Don't want to pry TOO hard that way though.

Maybe heat?

Search failed to uncover solutions.

Advice?

[djmossm42]

Yep just modify the firewall, here's a good write-up http://www.rmeuropean.com/bmw-e30-steering.aspx

My post with a few other sources, I went with an E46 M3 rack but same things apply to all airbag cars and rack swaps.

http://www.r3vlimited.com/board/showthread.php?t=374017

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[noahsense]

[QUOTE=Moriglioni;4558992]Anyone have a weird steering rack like this? '93 cabrio


That's just the knuckle for an airbag car, 1990-93. No modification to the knuckle necessary but you'll need to either modify the firewall slightly or build a custom knuckle.

[Moriglioni]

Steering knuckle**

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[Moriglioni]

Anyone have a weird steering rack like this? '93 cabrio


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[noahsense]

Thanks, I needed to confirm cause I already have my e30 hoses ordered and it would be a hassle to reorder e36 ones.

You'll find that this is a really sturdy part. I'm a skinny dude so I had to clamp it in a vise (w/ soft jaws or wood) and put some weight into it. Remember, adjust, test fit, repeat.

[marcusw]

You have asked this question in a few places, the answer is no. It worked for many people. If you are fearful of it, on a case by case basis, replace it.. your car.

Thanks, I needed to confirm cause I already have my e30 hoses ordered and it would be a hassle to reorder e36 ones.

[estoguy]

I said knuckle but I really meant flex disc/joint! Around $100 so not cheap but worth doing while everything is apart since getting it off can be a god awful pain.

I got a used one from a used BMW parts specialist outside Toronto for $50. It was a nice clean unit.

Getting out the old one was a bit of a pain. I would have done the engine lift thing, but didn't have one, so I did the bend-the-steering-rack-tab thing. It worked out pretty well after that.

[TimeMachinE30]

You have asked this question in a few places, the answer is no. It worked for many people. If you are fearful of it, on a case by case basis, replace it.. your car.

[marcusw]

Like i said a few pages back, I used my stock lines, I put the straight fitting on the power steering pump and the u shaped end on the rack. I had to open up the u shaped arch about 20-40 degrees but otherwise the stock lines fit without a problem. I was waiting to reply because I was going to take a picture for you.

Would bending the HP hose possibly cause the hose to break or leak easier?

[noahsense]

Good tips there! How much are knuckles going for these days?

I said knuckle but I really meant flex disc/joint! Around $100 so not cheap but worth doing while everything is apart since getting it off can be a god awful pain.

[roguetoaster]

Good tips there! How much are knuckles going for these days?

[noahsense]

How To Guide - E36 Steering Rack Swap

Just completed installation of an e46 purple tag rack [7852974678] and couldn't be happier. The steering is perfect and splits the difference between the standard e36 rack and some of the more aggressive racks. I think my turning circle shrunk too! Rackdoctor was great.

My car has an airbag so I had to modify the firewall; as someone else mentioned, a Dremel with tungsten carbide cutter [#9903] works well and since I broke the bit half-way through I'm glad that I had a spare. A flex shaft is absolutely essential if the motor is in the car and you’ll find it easiest to route from inside. A respirator is good insurance since the bit will turn metal, paint, and rubber into fine airborne particulate.

Other tips:
-Have a new steering knuckle/flex disc ready since the old one will definitely be showing wear.
-It’s not mentioned much but the slot in the knuckle/flex disc should align with the little divot on the steering rack shaft.
-While everything is apart on an airbag car, apply a good deal of Loctite Blue (avoid Red unless absolutely necessary) to the blue section inside of the the ‘Big Nut’ on the steering column. The Big Nut has an inner plastic thread locker which after one dissassembly is much less effective and tends to loosen and cause steering column shake over bumps. This really should be a one-use part but BMW never sold it alone.

[noahsense]

How To Guide - E36 Steering Rack Swap

On an airbag car, is it possible to install the steering joint upside down? I'm curious if this would move the shaft enough to avoid cutting the firewall.

[update] should be obvious to anyone who has done this swap - splines are a different size on each side

[LateFan]

We just did the swap. Standard E36 rack from Rack Doctor. HIGHLY recommend these people. Nice to work with.

We did the tab bend method, even though I hated to do that - just seemed like it would be way more time and complication to lift the engine. You just have to bend them back carefully so that your mounting holes line up.

Used the Dungeon Motorsports spacer kits. Spacers on TOP of the rack.

Steering coupler kit was nice, although we had to enlarge the holes just a hair for the bolt size. That odd clunk we always had in the steering was I think a broken fitting in the coupler recall kit that was on our car. Noise is gone.

We thought we had cleaned up / enlarged the coupler U-joints enough, but ended up hand filing with a rat tail file to make clearance. A Dremel wouldn't fit due to AUTOMATIC TRANSMISSION plumbing...I know...

It's the upper U-joint at the brake booster that mostly needs the attention so it doesn't bind. (We have a non-airbag '86)

We put the high pressure line with the 180 metal bend at the pump - works fine without bending it, although it is up against the lower radiator hose. Don't know if that's an issue.

Installed new E36 tie rod ends from Rack Doctor. Totally eyeballed it before we ran it over to the alignment shop......10 degrees off, oops.

Steering is so much better - tight and quicker, solid. A giant improvement.

Thanks for the guide and advice, OP and all.