How To Install A Rack-And-Pinion Kit

28 This photo clearly shows our setup underneath the hood. Note that we had to dimple one header tube to provide clearance for the rack input. We were lucky that's all that was necessary. A manufacturer can't anticipate every possible header and clutch combination. We suspect our predicament would have been far more difficult if our engine had shorty headers. We were a little concerned about clearance for the clutch shaft initially, but the steering-connection shaft cleared the cross-shaft with plenty of room to spare.

29 The next step is to install both of the universal joints needed for the connection between the steering wheel and steering rack. This one is splined to accept the rack input shaft while the others were designed with flat-sided circles to fit the furnished shafts. Each U-joint has two set screws at either end, and when the final assembly was made, they were secured with a thread-locking compound such as Loctite.

30 Here, the crucial measurement is made for the connecting shaft. The instructions specify that the shaft must extend into the U-joints for a distance of one inch, all the way up to the shoulder of the U-joint, but no further. While using a shaft cut too long would cause binding, we want the maximum connecting distance. Our measurement is exactly 3-3/4 inches.

31 Using the provided stock, make the measurement mark using a laundry marker, and secure the shaft in a bench vise. We fitted a circular saw with a carbide cut-off blade which made short work of the job.

32 In order to install the connecting shaft, we had to slide the steering column back a little, and the new piece fit right in. Here, the Allen-set screws are tightened.

33 With the final connection made, the steering column is permanently installed at the column base and underneath the dash. All steering rack fasteners underneath the car are also tightened for the final time.

34 Take a look at our final column-to-rack connection. It's a slick-looking and bulletproof arrangement that clears everything nicely.

35 Mount the KRC power-steering pump to the engine using the supplied bracket and spacers. Since our car is a no-option strippo, the pulleys are all single-groove. We're probably going to switch to double-groove pulleys, since we don't want to run the alternator, water pump, and power-steering pump off one belt.

36 Included in the kit are these top-quality lines which can be assembled at home without special crimping tools. There's no need to visit an air-conditioning shop or other hydraulic-hose shop to get the system up and running. The main concern regarding the lines is cleanliness. Any foreign matter such as rubber particles or dirt will destroy the pump in short order. TC recommends cleaning them with a rifle bore brush, followed by soap and water, and compressed air.

37 Our car had plenty of space available for mounting the power-steering fluid reservoir. Select a location above the pump. Be sure the reservoir is filled before firing the engine. Running the pump dry for even a short time will damage it.