today at work i am finally doing a 1st gen SC rack. its been a while since there is not a high demand for them. i just wanted to show you guys how it is done. i highly doubt anyone will try this.
Rebuild Rack Seal kit (Kotek & Transtec) Transtec is double the price of Kotek, but they both do the job. i get fewer defects with transtec kit.
New rack boots
New inner tie rods
Vise mounted to a sturdy table. ( do not attempt if you do not have this)
Various size punches (see pics)
2ft or so punch (see pics. also do not attempt if you dont have this)
Flat blade screw driver
Channel lock pliers
6mm allen key
(other various sockets. see pics)
12mm wrench (tubing wrench preferred)
Snap ring plier
Needle nose plier
LOTSSS OF RAGS
Bucket to catch old PS fluid.
Carb cleaner to clean your rack.
U-joint from your car to steer the rack. the one that is connected by 2* 12mm bolts (no pic)
1. mount your rack to the vise. take of the old boots (no pics) rack is super dirty. you can use carb cleaner to clean the rack. sometime the cleaner will take off the paint from the rack. it isnt a problem for me since i paint them after im done. i have a part washer tub to clean my racks. i use carb cleaner once in a while.
2. how it looks without the boot. take your flat blade and tap the lock washer at the folds (2 folds per tie rod)
3. take your monkey wrench and loosen the inner tie rod on both sides. make sure the rack in mounted tight to the vise. righty tighty lefty loosey
4. some times the kit wont come with new lock washers. dont worry you can reuse them. take the plier and use a hammer to flatten the washer. you can put the washer on the flat part of your vise. dont flatten the two small tabs. see ARROWS in pic
5. your rack should be clean by now. remount the rack on vise. loosen and remove the adjusting nut. you can use the monkey wrench to loosen the lock nut.
-loosen lock nut w/ monkey wrench
-HOMEMADE tool i made, but not needed. 24mm nut welded to a rod. makes it easier but can use snap ring plier.
-this is what should come out and how it looks after.
6. Using the U-joint from your car. steer it the the right? and remove snap ring. (im using a HOMEMADE tool) careful when steering, there is PS fluid in the rack. place bucket to catch old fluids.
-showing my home made tool.
-snap ring is on the passenger side of the rack.
7. remove the 2* 14mm banjo. careful there is 2* washer per banjo bolt. 12mm wrench to remove the hard lines. i only remove one line and loosen the other since it isnt really needed to remove both, but you can if it gets in your way.
-the line with the wrench is the one i remove. the other i just loosen.
-fitting after line in removed.
8. remove the 2* 6mm hex bolts with allen wrench. one on each side. remove the cover. the flat blade screw drive will help you pry it off.
9. remove the 27mm nut and 17mm nut. when removing the 17mm the shaft will move. careful because old PS fluid will leak. keep turning the 17mm SLOWLY
till the shaft locks and you should be able to loosen it.
-after the 27mm is removed, the 17mm is exposed.
10. remove the steering valve. should come right out or use flat blade to help. remove the the washer and bearing after the valve. a quick tap with a ratch will take them out.
-washer and bearing inside
i am still adding. i just post so i dont hit the back button and have to redo everything.