MK4 Steering Shaft / Steering Wheel boss fitment problem

[Jeff_J.]

I've run into a problem with getting the upper steering shaft into the steering wheel boss - it appears the flat part of the steering shaft doesn't line up with the flat portions of the steering wheel boss, it appears to be misaligned by a very slight amount. I understand there have been a couple of builders who have run into this as well. It would seem taking a bit off the upper shaft would be the answer but I was wondering what others who ran into this have done.
I have the Russ Thompson Turn signal mod but like he said his work does not affect the fitment. Any comments from the group would help.
Thanks Jeff_J

[Papa]

Have you centered the rack? Once centered, adjust the shaft at the splined connector to the rack to align the boss as close as possible, then a final front-end alignment can easily center the wheel.

[Jeff_J.]

Hi Papa, I probably didn't explain this well.
175073
175074
The flat section of the Upper Shaft does not alight with the flat spots in the Steering boss. I was in the process of roughing in the Russ Thompson Turn Signal when I discovered the steering wheel boss would not fit onto the upper shaft. It appears the two flat spots are out of alignment - I have heard others have had this issue, just wondering if sanding a bit off the shaft was in fact the only fix. If the Boss wasn't already adjusted by Russ T I would have reached out to Factory Five for a replacement - I still may have too. It isn't just a matter of turning the shaft, if i do that the other flat spot is out. Thanks for you input none the less. Jeff_J
(still use your build as a reference)

[edwardb]

Highly recommend to not modify the steering shaft. It's hard to tell exactly what the issue is from your pictures. But the boss is relatively soft aluminum. Unless it's way off (again, can't tell...) if you put the Allen bolt with a large washer on the shaft and draw the boss down, I'll bet the aluminum will conform. Just be aware that even when they fit perfectly, it's a tight fit. As it should be. Takes a puller to get it back off. I've been using this $18 one from HF for years. https://www.harborfreight.com/bolt-type-wheel-puller-set-62620.html

[ydousurf]

I had a similar problem with mine. I actually chose to modify (file & sand) the aluminum steering wheel block/boss to make it play nice. I used the ol' persuasion tool "big hammer" and began the imprinting pattern (if that makes sense) in the aluminum to begin to develop the new slot, and then finalized it using small/med round and flat files. I didn't want to alter the shaft, since the aluminum piece can be the sacraficial part. As long as there is good solid fitting between the parts it shouldn't be an issue at all, once it's tightened down. And we're not 4-wheeling with these, where as, one tends to pull on the steering wheel and stress it in certain ways other than casual turning left or right. Anyway, I hope you get it slotted/seated nicely. All the best in overcoming the unexpected.

Doug

[Papa]

Hi Papa, I probably didn't explain this well.
175073
175074
The flat section of the Upper Shaft does not alight with the flat spots in the Steering boss. I was in the process of roughing in the Russ Thompson Turn Signal when I discovered the steering wheel boss would not fit onto the upper shaft. It appears the two flat spots are out of alignment - I have heard others have had this issue, just wondering if sanding a bit off the shaft was in fact the only fix. If the Boss wasn't already adjusted by Russ T I would have reached out to Factory Five for a replacement - I still may have too. It isn't just a matter of turning the shaft, if i do that the other flat spot is out. Thanks for you input none the less. Jeff_J
(still use your build as a reference)

At some point along the way, the orientation of the boss was changed by FFR. When I ordered my RT turn signal, Russ asked me which boss I had. I had to confirm with him what the orientation of the flat part of the shaft was so that he could machine the boss to work correctly. I can't tell if this is the issue you may be having, but worth exploring. The difference would be very obvious as I believe the orientation change is 90 degrees different.

[Jeff_J.]

Hi Paul, Tough to take pictures with one hand and hold the piece at the right angle but I'm getting better. You have a grasp of what I'm dealing with, I thought about drawing it in as well I was concerned about applying too much pressure and ploughing through the aluminium. I'll take a look at this again and apply a lot of lube before starting. I'm sure once it's on it would be a bear to remove..
Appreciate the input!
(by the way Truck Looks Great!)

[Jeff_J.]

Hi Papa,
The flat spots on both the shaft and the boss are ever so slightly off so it's not a multiple degree difference, just enough to make me concerned about applying to much pressure and damaging the aluminium boss. I'm thinking between different sources of supply there might be a tolerance deviation between pieces of an assembly. Thanks for your comment, it all helps.