Bad Steering Rack?

[karlos]

Maybe I'm not understanding, but something seems out of sorts. I'm trying to get a rough setup on my front end but can't make sense of what's happening with the tie rod ends. I have a manual steering rack, which is installed and centered as shown by the first couple photos. I have the front wheels pointing straight ahead using a string from the rear wheels as a reference. The inner tie rod on the driver's side is screwed in to the outer tie rod end so far that I'm about out of threads (bottomed). Meanwhile, over on the right side, the inner tie rod is turned out more than an inch further than the left. The photos show way more exposed thread on one side versus the other.

When I measure the extension of the steering rack I see the same one-inch difference. The right side is one inch shorter than the left (about 6 inches measured to the vertical frame rail versus 7 on the left). The rack is centered, so shouldn't the extension of the inner tie rod ends be about the same? Bad rack or is this just how these go together?


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[edwardb]

Can't see your steering arms in the pics you posted. But I'm going to assume you have them installed on the correct sides. This is a common mistake, but doesn't sound like what's happening. There is mechanical centering of the rack in the frame, which is pretty locked down and in the Mk4 pretty accurate. But there is the center of the rack movement, which sounds like what you're describing. How did you determine this? It should be by turning the rack all the way to the stop one direction, then counting the exact number of turns to get to the stop in the other direction. Divide this number in half, and turn to this exact location. From here, you should be able to turn the exact amount to the stop either direction. Check it several times just to be sure. From there the inner tie rods should be equal length on both sides. If not, then something maybe is wrong. Note at this position the steering wheel will likely not be centered. You will need to rotate the steering column adapter at the rack to this location to center the wheel.

[CraigS]

A couple of things come to mind.1- I can't tell from the angle of the pictures so will ask, is your camber set same on both sides? 2- Since you have the column connected and the wheel on, use this to check travel as EdwardB says. The rim of the wheel vs anything stationary gives a good reference using a piece of painters tape to mark the wheel. 3- Your tie rod ends look to be the same on both side but I can't be sure about the tie rods. There are different lengths available I think so it would be good to measure them. 4- I can't tell for sure, but your frame seems high to me. What is the height off the floor?

[Svtfreak]

I agree. Sounds like each wasn't centered when installed. Follow Edwards procedure to center and see what happens.

[karlos]

Thanks for the help, guys.

The steering arms are installed correctly, I believe. Angled outboard; big end of the tapered hole down. I rechecked the center of the rack movement and gained a bit of improvement there. As Edward said, the steering wheel is not centered when the rack is. In this new position the inner tie rods are centered in the rack as near as I can tell. But I definitely don't have equal thread engagement in the outer rod ends with the wheels pointed straight ahead.

Camber is set at -0.5 degrees both sides. The frame looks high because I need to raise it 2" in the front to account for the slope in my garage floor. Frame is at ride height and level, and I have supports under the wheels/tires to get the suspension at the right height relative to the frame.

I just took a closer look at the way the rack sits in the chassis. It's shifted to the left about a half-inch. Photos aren't great but you can see the offset. I think this explains what I'm seeing. If the whole rack is shifted by half-an-inch, then one rod end will be a half-inch shorter and the opposite one a half-inch longer for a total difference of 1 inch.



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[edwardb]

I'll be curious what others say, but I don't think measuring from the edge of the boots is necessarily accurate. Also, I see you have a Mk4. Off-center rack mounts were a problem with previous Mk's. But for the Mk4, FF fixed it. Both of my Mk4's have been dead on. My recommendation is to cut the straps on the boots at the big end and slide them out of the way. Then with the rack travel centered as I described before, you can confirm exactly where the inner tie rod attachments are. They should be exactly centered. If not, maybe the rack is defective.

[karlos]

Bad rack.

Edward nailed it. With the boots out of the way and the rack movement centered there is a clear 1/2" bias to the left. Looks like I'll be giving FFR a call tomorrow morning.

-Karl


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[karlos]

Some more photos. The first shows the right side of the rack when centered; the second shows the left side. With the rack centered, the position of the steering wheel is marked with a piece of tape and a laser (third photo). The tape has a black dot that rotates with the wheel, while the laser position is fixed on the wall behind the car.

The fourth photo shows the position of the dot relative to the laser with the wheel full lock right. 1 and a little less than 1/4 turns.

The fifth photo shows the position of the dot relative to the laser with the wheel full lock left. 1 and almost 1/2 turns.

Not even close to the same rotation on the steering wheel from center to full lock right and full lock left. Rack's definitely bad...




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