Date:         Tue, 7 Sep 2004 09:09:46 -0500
Reply-To:     Andy Stalick <andystalick@GMAIL.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Andy Stalick <andystalick@GMAIL.COM>
Subject:      power steering rack replacement
Content-Type: text/plain; charset=US-ASCII

So I am in the midst of replacing my power steering rack. The old one
came out with minimum problems. I flushed out the hydraulic system by
placing a bucket under the open hydraulic lines and cranking the
engine over until the fluid ran clean. I bolted the new rack into
place and got the tie rod ends in place in a reasonable approximation
of straight.

But I can't seem to get the steering rod and u-joint assembly into
place. The u-joint doesn't slip as far onto the rack's splined nub as
far as it did on the old rack, and consequently I can't get the two
plates on the other end to line up. I tried hammering it , and its
gotten tighter, but there's still not enough clearance. Now I'm not
even sure I can get it back off to try something new. Does anyone have
a tip for this last part of the job?