Had a go at this corsa steering rack mod today. Corsa linkage cost £6 in the 'yard and there is no shortage of them. In case anyone else is thinking of doing this I'll jot down the steps as the wiki leaves a little to the imagination.
1. I used a hack saw to remove the corsa universal joint. This is the non-splined end that we are discarding. The metal is fairly soft and easy to hack saw through.
Be careful not to saw through the bearing shells (why I used a saw not a grinder)
2. Repeat on the opposite side, leaving you with this
A quick tug and it should come apart
Leaving you with this (keep)
and this (discard)
Put the corsa linkage to one side for a moment and turn your attention to the bmw linkage. I used an e36 but it would be the same if you were using your e30 linkage.
3. Use a grinder to lop off the upper part of the e30 linkage
below the UJ. I did this to allow me better grinder access for the next step. The metal surround will just fall off allowing you to get in there with the cutting disc (this will become clear in the next pic)
Now it's easy to see what needs to go
4. Make two cuts as shown by the red arrows
Probably best not to try and take a pic during, but sparks are cool!
You're left with this
A quick application of the lump hammer should break off any remaining metal
Remember this will be hot hot hot, pliers not fingers
5. Lock your UJ in a vice and punch out the bearings. Your'll probably find the little cylindrical rollers will fall out and get lost but it doesn't matter as we are using the ones from the corsa.
Be careful as this will still be hot from the grinding.
You will be left with
6. Using a round file smooth off the guide holes. You want the corsa shells to fit in there snugly and not be too loose. I would file a little and test fit until you think it will just about squeeze in. Patience needed here.
I added a little extra copper grease to the shell to help stop the rollers falling out during the next few steps.
7. Insert the corsa linkage into the e30 upper UJ, push the shells in from the outside so they seat on the bearing.
Like this
You might need to use the punch to get them seated correctly both sides.
8. Take your punch and hit the aluminium surround hard to stop the bearing sliding out.
Like this
Four should be enough, make sure you do the other side as well
9. Now its just that pesky master spline to file down and you're done.
It feels very solid, quite pleased with the result, I will be trial fitting this set up soon.
, I can't wait.
.
