So I've got my 1992 2wd up on the lift trying to replace the leaking rack and pinion. Got the old one off, which wasn't bad other than the roll pin in the u-joint to splines shaft connection. Well of course that part is being even harder to get back together.





Anyone have any protips or techniques to get it to line up? I can't quite seem to get the flat spots to align, much less press it together once they do. I had to use the air hammer to knock out the pin and press the joint apart, so not really sure how to get it together easily. Thanks guys.

 

Clean the splines REALLY well, some variety of penetrating lubricant, and a little wire brush. Some anti-sieze in there isn't a bad idea. Get things lined up as best you can, then move the wheels to get it exact. Probably have to tap it down with a hammer....

 

I'll add that you can remove the bolt holding the rack on that side, and loosen the bolt on the passenger side, to get some swing into it.

That's what I did until I rebuilt the intermediate shaft, anyway.

RwP

 

Cleaning up the splines is a good one. I didn't have a small round wire brush to fit in there, but I'll get something. I tried anti seize on them but cleaning it out is a good idea. I might need to have a buddy assist me with turning it as I'm pressing them together. Problem is I can't just bolt the rack down tight, because the u-joint doesn't bend hard enough to fit. So I have it kinda hanging loose from one bolt and trying to fight the wiggle in both that and the u-joint.