Steering Rack Coupler Problem. Topic is solved

cmbfoto · Post by **cmbfoto** » 05 Jul 2021, 17:43

Im installing a new P/S Rack coupler. The U-Joints are worn out and causing too much play in the steering wheel. Removed the interior pinch bolt to the coupler and rubber boot. Sprayed the lower pinch bolt down removed that bolt. Now the coupler is frozen to the steering rack shaft. Tried to gently pry her off from under the dash but no go.... Need Help With This One.

Post by **vtl** » 05 Jul 2021, 22:02

It could be the rack itself. Remove the rubber boot and try to wiggle the coupler below the U-joint.

That was the end of my steering rack:

As for the coupler, you can try to smack it off from beneath (the car should be on the ramps) using a long 1/2" extension, but it will likely damage the shaft seal. The safest approach is to lower the rear of the subframe, remove the anti-sway bar and cut the coupler with a Dremel.

But save your time and check the rack for play first.

Post by **oragex** » 06 Jul 2021, 06:04

As above, too much - or perhaps even little forcing may damage the rack box shaft seal. Even the penetrating oil that you sprayed on will usually leak on the top of this seal and can damage it. Try to cut off without damaging the rack shaft

Post by **jonesg** » 06 Jul 2021, 07:24

after removing the pinch bolt try inserting a screwdriver blade and prying the slot open a bit to break the bond to the shaft.
Also try inserting the pinch bolt backward, block the slot with a knife blade, the pinch bolt should push the slot wider.

Post by **vtl** » 06 Jul 2021, 07:36

After decade+ of permanent heat/cool/salt/water the aluminum and steel weld into each other. I was removing it forcibly with a small sledge hammer (5 lbs or so), it was tough. In my case it was fine to destroy the rack (which I did), because I had a factory rebuilt Bosch-ZF laying nearby.

Also the space around the coupler is very limited, you could do only so little without dropping the whole steering rack.

Post by **abscate** » 06 Jul 2021, 09:00

I sweated the same problem on the T5 and had to remove the rack to get that coupler off. It really rusts on. Chance of damaging the rack is really high with chisels and other 'methods'

cmbfoto · Post by **cmbfoto** » 06 Jul 2021, 15:17

I want to thank everyone who replied to my situation. Yes living in Syracuse NY aka the Salt City reeks havoc with aluminum. Getting a closer look at the joint the prior owner was trying to replace it way back. Shes got 185k and brought her back from the dead last year when the CAM seal blew.

I was able to use two short blocks and a pry bar to pop the coupler off with out damaging the rack. The new Volvo coupler went on easy and the steering is tight no side to side play. After my road test I noticed we had no horn, no audio controls. Just Great...[img]