power steering rack fitting! HELP

[jak_thrice]

hello everyone, i got a power rack system off a zoner and tried to fit it to my 1988 320i (with no p/s) and it doesn't fit properly. i have been trying all weekend and it just wont go on! i've got the rack in but having trouble with the couplings, so i took out the drivers side bolt on the rack then managed to get the upper coupling to bolt up, i then levered the rack a bit to get the long bolt to get through the mounting holes. i then turned the steering wheel a couple of times to how it was and the bottom coupling came straight off. with the rack bolted up on the rear holes the coupling is about 2cm short, at a stretch the lower coupling just touches the rack splines. what do u think i should do?

[jak_thrice]

forgot to say im not blaming the zoner i got it off, top bloke!

[ian332isport]

Are you also using the power steering coupling ?

I believe the manual and power couplings are a different length.

Ian.

[Brian28]

Hi, it came off an identical car in one lump, ie rack and coupling together. I've been in contact with Jack over the last day or two, basically when fitting it to Jacks car it seems like the coupling is a couple of cm too short. The rack is definitely mounted in the right bracket holes, ie the ones closest to the subframe, so we are running out of ideas. I've measured two different couplings here (p/s) and they all seem the same length. Is there any particular sequence or anything when fitting these things? I've not run into this problem before so not sure what to suggest, any ideas welcome.

Cheers
Brian

[Demlotcrew]

You can pull the coupling out/appart slightly this will give you enough grip on the lower splines.

Andrew

[jak_thrice]

safely how far should the bottom coupling be on the splines?

[Martinaston]

You can fit it without moving the rack out of position.
You have to slide it onto the rack splines first as far down as it will go and then you should have just enough clearance to get the other end onto the column and then slide it back up the splines (hammer), but only hit the bit that attaches to the column or you ruin the universal joint.
and THEN put the bolts in.

[jak_thrice]

when i do up the upper coupling where the bolt can only go through in one place the other end slips off, as if it were too short! agggghhhh!!

[Martinaston]

Is the coupling the right way up ?

[jak_thrice]

Yes! it can only go one way up, im sure as the top one has the grove for the bolt to go through, and the bottom fixing doesnt have the bolt coming through onto the splines.

[Martinaston]

The rubber doughnut in the middle should be nearer the top.

[ian332isport]

Is the coupling the right way up ?

It will only fit one way around. The bottom splines are much finer than the top ones which are quite chunky.

Ian.

[Martinaston]

Its still possible to get it on the wrong way round, i guess he has the wrong one. Or he needs to push the steering wheel down a bit

[ian332isport]

Its still possible to get it on the wrong way round

Not unless you're an Ape with a very large hammer. You certainly couldn't do it by mistake

[Martinaston]

He still hasn't replied

[Brian28]

, i guess he has the wrong one.

Does anybody know if there is more than one type of coupling for PAS? As far as I know there are only two types, one for manual and one for PAS. Jack probably hasn't replied because, unlike some of us , he has a life so doesn't spend his evenings on here. The car isn't at his house so he wouldn't be able to have a look at anything/check anything until tomorrow in any case.

Cheers
Brian

[Martinaston]

did you sell him an E36 rack by mistake ?

[Brian28]

Nope, here is the rack in my 320i a couple of weeks ago. It's literally been removed from my car as one unit (coupling, reservoir, pipework, pump) for transplant into Jacks car, another 320i. So I'm baffled. If he is around tomorrow afternoon I may go for a look.

Cheers for the suggestions
Brian

[Martinaston]

Must admit i'm stummped, did you rip that engine out ? that mount looks shagged

[jak_thrice]

sorry been out to the pub! dont worry i look after rally cars for a living i think i'd know if id put the wrong fitting on a spline! thanks brian!