Steering Column/Splines to Rack

[ck_taft325is]

Replacing my rack I hit a snag. The old came out fine following the Bentley procedure. Took a few hints from the e36 rack swap DIY, but hit a huge problem getting the new rack splined onto the knuckle. Still can't get the damn thing splined, any hints or tips?

Also, while trying to spline it, it disconnected from the inside of the steering column itself (32MM nut right in front of the firewall from the inside of the vehicle). If I spline the knuckle to the rack then the shaft into the 32mm nut is a pain/impossible to get reconnected. If I connect the two shafts (steering wheel column to the shaft that goes to thru the firewall to the knuckle) then the knuckle is totally stationary. I think connecting the shafts is the first step then tackling the knuckle>rack spline.

Any suggestions or tips? This was not supposed to take a day + at my buddies house. Currently my only form of transportation, so I'll be eternally grateful to any advice on this. I'll send 2 dozen of your favorite cookie to any winning strategy :D

It's a '91 318is and I purchased the rack from Joe318is who had used this rack previously in a '91 318is.


Thanks a billion in advance!

Christopher

[ck_taft325is]

Shaft's are splined back together.

Still can't get the knuckle splined onto the rack more than the first 1-2 mm. Has to spline all the way on, yeah? Just seems waaaay too tight to fight but I checked the old vs new and it's the same. And as before mentioned, came off a car of the same model/year.

[jlevie]

It may be that the spline on the rack is slightly rusted, which will make it very difficult to engage the rack shaft and coupler. Probably not what you want to hear, but I'd remove the rack and clean the splined shaft until it is bright metal. I'd remove the coupling and clean it also as well as test fit it to the shaft. When everything will go together normally, re-install the rack.

[arch4ngel]

I had to spray some triflow on the splines and jiggle back and forth with a vice grips + rag before it would even budge.
19 years of crap and a very tight fit.

[ck_taft325is]

It may be that the spline on the rack is slightly rusted, which will make it very difficult to engage the rack shaft and coupler. Probably not what you want to hear, but I'd remove the rack and clean the splined shaft until it is bright metal. I'd remove the coupling and clean it also as well as test fit it to the shaft. When everything will go together normally, re-install the rack.

Good news is that I cleaned up the splines on both knuckle and "nipple". Both where in great condition already.

Define "go together normally"? Pulling the rack doesn't bug me much. Done it a bunch already with the in and out. You're suggesting remove the rack, and knuckle then test fit them together and re-install? Would you suggest pulling the coupler (knuckle) from the shaft that goes through the firewall or remove the top nut and "un-spline" it from the shaft that goes through the firewall?

I got the coupler/knuckle past the first set of threads from the rack "nipple" but cannot get it to budge further. Do you think C-clamping, given I have enough space, the coupler/knuckle and rack splines together give me anymore play?

[twistednut]

First, how much of the firewall did you cut away? I couldn't get mine to line up without removing about 3/4 of an inch. Second, you just need to spread the knuckle more with a big screwdriver.

[ck_taft325is]

Got it in but still suffering from some leaks. Can't trace if it's the rack leaking or the hoses going to each and/or either banjo bolts... It runs though.

Previous owner some how managed to disconnect the PS pump and the pivot bolt on it, so I've got to trace down something that fits before I can even try the PS'ing.

"twistednut" - I didn't have to remove any of my firewall. It literally slid right out and I just stabbed it back in once I finished removing the knuckle. Splined the knuckle/coupler onto the shaft that goes through the firewall, reconnected and went from there...

[ck_taft325is]

As a side note, this rack is insanely nicer even without the power steering hooked up all the way. I have it re-circulating through the banjo's. Not to mention getting the splines correct on the shaft that passes through the firewall really stiffened up the steering feel while braking down hill.

Replaced the Tie rod/assemblies while I was down there. Anyone else find those bent over lock washers to be a total pain in the ass?