DECODER22
Supporting VIP
- 325
- 9
- Jul 20, 2004
-
Janesville,
Wisconsin
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:
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, dirty, greasy, blown rack.
I will get a more detailed writeup with more pictures with another set. When doing this one I wasnt really expecting to do a writeup with pictures and it was done rather fast so I didnt get a chance to get everything documented.
i was going to take the lines off and cap them but i didnt want to hunt down the right size plug
it seems with the power assist removed and the fluid taken out, torsion bars welded etc it for some reason it turns real smooth and easy i mean its hard to explain i guess without coming over and trying it yourself ill work on a better write up with details. i am going to talk to the guy i was working with about the reasons of why its easier and explain all the details
sorry for no update ill have the full write up done in a few days i was out of town
sorry just been busy the place i went to does not deal with the public they only deal with part stores such as auto zone etc ill have the write up this weekend also soon as [plug deleted] gets there site and store up and running there going to stock them most likely, I'm trying to find a few more cores and get a few more people to test them on there cars if anyone is interested in testing let me know
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, dirty, greasy, blown rack.
I will get a more detailed writeup with more pictures with another set. When doing this one I wasnt really expecting to do a writeup with pictures and it was done rather fast so I didnt get a chance to get everything documented.
i was going to take the lines off and cap them but i didnt want to hunt down the right size plug
it seems with the power assist removed and the fluid taken out, torsion bars welded etc it for some reason it turns real smooth and easy i mean its hard to explain i guess without coming over and trying it yourself ill work on a better write up with details. i am going to talk to the guy i was working with about the reasons of why its easier and explain all the details
sorry for no update ill have the full write up done in a few days i was out of town
sorry just been busy the place i went to does not deal with the public they only deal with part stores such as auto zone etc ill have the write up this weekend also soon as [plug deleted] gets there site and store up and running there going to stock them most likely, I'm trying to find a few more cores and get a few more people to test them on there cars if anyone is interested in testing let me know
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