marcelosm

I've begun the process of replacing the manual rack and pinion on my Sol and have run into a brick wall. I got up to the point where the rack is loose but I can't for the life of me get it out.

I've already dropped the exhaust and that helped a bit but I still need more clearance. I've read that undoing the shift linkage can help (I already followed the link in the FAQ about getting the spring pin out with a c clamp).

Is this the only thing that I can loosen to help make space? Any other tips for removing it? Thank you.

Former User

List all steps where you have deviated from the service manual instructions.

rudebwoy

iTrader: (1)

have you disconnected it from the steering linkage? if you have try removing the tie rod ends that should give you more movement.

marcelosm

Unfortunately I don't have an FSM, but I will list in detail the steps I have taken so far.

Jacked up the car and put it in stands. Removed both front tires.

Loosened the outer tie rods a bit. Removed cotter pins and removed castle nuts. I used a tie rod seperator to pull the tie rod out of the steering knuckle.

Removed the outer tie rods (have replacements on hand). I then climbed into the car and pulled open the steering column and undid the 2 bolts to seperate the rack and pinion.

Climbed under the car and removed the 2 spring bolt things on the exhaust and lowered it down to make room.

Undid the 4 bolts holding the rack and pinion. It is loose now but still doesn't clear.

Former User

The diagrams are for the 92-95 Civic, but the Del Sol is likely very similar:

marcelosm

Okay that's exactly what I need. I wish I could get my hands on a physical copy of the FSM. Thank you so much!

Former User

Try Google searching for the FSM.

...or PM TomCat39. He posted a link to the Helms Manual site. The prices for old service manuals are very reasonable.

marcelosm

Hmm I will definitely look into it now. I was previously working a job that barely left me any money and so it was a bit pricey from that website. I finally got a job as a teacher so the money won't be as tight anymore. Thank you for posting those Ron

ejv8s10

Del Sol:
Maybe this pic will help

marcelosm

Well I got the rack out today with little problem after following the FSM. I had ordered the new rack from rockauto. The last thing on my mind was if it was going to fit properly but when I compared the two I noticed that the rubber piece that gets bolted on the passengers side was not lined up. I put the two parts side by side and there was a slight difference.

The rubber part was too far to the passengers side and the holes would not line up. I tried moving the rubber part over and I had no luck. The part I ordered was an aae 4223n manual rack and pinion. The one I received has a stamp that says aae 10y13. I tried searching google but that part number doesn't seem to exist and rockauto doesn't carry it either.

Has anyone run into this problem before? I'm going to call rockauto tomorrow and see what happened as well.

Former User

I think you'll get the issue resolved by doing this^.

You could also post pictures of the 2 racks side by side to get feedback here.

marcelosm

Let me post the pics I took. It was dark but I think they work

marcelosm

Q

marcelosm

Former User

Which is from Rock Auto and which is the original?

marcelosm

Rock auto is the bottom lighter newer on that has intact boots. Old one is black with oil and grime and boots are broken

Former User

It looks like the wrong passenger side dust boot may have been installed on the original rack and it was also installed in the wrong the location. The passenger boot on the Rock Auto rack makes more sense to me.

But are you saying that the two bolt holes near the valve body of the Rock Auto rack also do not align on your car?

marcelosm

Yes. The original rack fits perfectly. The c shaped metal piece that has two holes in it for bolts fits in a rubber piece on the passenger side. On the original it fits in the right spot and the holes line up. On the new rack if I put it on the rubber piece the wholes do not line up. It has to be placed almost halfway off the rubber piece to make it fit.

The two bolts on the drivers side fit perfectly. Its the other two on the passenger side that do not line up.

Former User

Are you able to transfer the rubber cushion and bracket from the original rack to the the new one?

marcelosm

I may be able to, but I haven't tried it. The thing that was off putting is that there is an actual difference in the lengths of the racks. It is slight but it is definitely there. I'm not sure if that is important but I thought it was.

Switching the cushion between the two seems feasible but I would have to take the boot off and put a zip tie on it?

Former User

I'm not sure the slight length difference is a big concern given that the tie rods allow the length to be adjusted during the alignment.

The rack would probably install fine if you transfer the rubber cushion and bracket from the original rack.


The odd thing to me is the passenger dust boot and its unusual placement on the original rack. That doesn't look right to me.

marcelosm

Well maybe its just because it is so broken? Well I will try and transfer the cushion tomorrow and see if that does anything. It doesn't seem like the cushion needs to be particularly secure since it gets bolted down. I might try and just cut it loose so that it can slide freely from side to side so that I can align it with the holes.

While you are here Ron, is there a trick to getting the rack aligned perfectly so that you aren't even a single tooth off? I saw some people mention to count the number of spins it does when you go from one side to the other and divide by two but it seemed a bit inaccurate and I may be off by a tooth. Is there a more precise method?

Former User

For Civics, there's no need to cut the rubber cushion. It is not a complete circle. It has a split on the bottom that allows it to pop right off the rack.

If I remember correctly, the rack valve body has an alignment mark that tells you the straight forward position. You just need to center the rack by making the right and left side inner tie rods equal length.

marcelosm

I really hope that is the case. Either way I'll go ahead and update you on that tomorrow. Thank you for your help Ron. Goodnight

Former User

Also be sure to contact Rock Auto.