MK4 Upper Steer Shaft Too Long

[rsbrillhart]

Seem to have run into an issue with my steering column. I installed the lower shaft unit through the flange bearing on the foot box. But now with the upper column, I slide it through the pillow bearing, but only about 2" (first recess) goes in before it gets very tight. I still have another 3" before the second recess. I have 7.75" of steering shaft on the drivers side pillow block, which seems about the right distance. If I hammer the shaft to get the 2nd recess in, I'll have less than 5" of steering column in the cockpit. Does that sound right?

111579

[Ducky2009]

Should be snug but able to slide together without hammering. Measure (with calipers) both parts, shaft and slot, and check for burrs. Measure the flats and round shape. You can sand/fine a little if needed, or cal FF for a replacement part.

Did you install the conical washers in the first set of recessions? If so, leave them out for now while while trying the initial fit.

[cv2065]

As Ducky said, don't hammer it. I did and it got all jacked up. I asked FFR for a replacement. Really shouldn't take more than a slight tap tap to move it, even with the conical washers in place. More than likely you'll have to adjust a bit when you put your steering wheel on, so it needs to move easily.

Also, test the rotation of your steering shaft. If it catches on the 2" beam then you'll need washers at the pillow block to raise it up a little. My instructions still had the old pillow block location and didn't mention that.

[rsbrillhart]

Thanks for the reply. Realized now that the upper shaft will slide into the lower shaft easily. The issue instead is the upper shaft stopping at the pillow bearing. It slides through fine with the portion of the shaft that's been milled to go into the lower shaft, but as soon as the round shaft portion gets to the bearing, it stops. Seems like that may be by design, but then I still have about 3" left before the 2nd recess goes into the lower shaft. Any suggestions?

[rich grsc]

As in post #2, take some fine sandpaper and clean up the shaft.

[silver_pilate]

Overly simple question, but have you backed out BOTH the set screws on the bearing? Also, my upper steering shaft surface rusted after I installed it, so you might consider a very light coat of clear before you install for good after you make things fit.

[GoDadGo]

As in post #2, take some fine sandpaper and clean up the shaft.

Ditto On The Sand Paper Column Clean Up.

I used 600 grit to clean mine up then put some wheel bearing grease on on the sucker and slid it in.

Remember to make sure you put the little spring washers in too.

[rsbrillhart]

Thanks for all the replies. Inspecting the shaft more closely, there's a very small burr where the machining stopped on the sidecuts. Barely see it, but can feel it. I'll sand that off and go over the whole thing with 600 grit as suggested. Very much appreciate the guidance!