Lotus Elan

Steering rack strip-down (ish) !

PostPost by: l10tus » Wed Jun 28, 2017 12:08 am

Attempting to take my rack apart to investigate play showing at the steering wheel, but can't for the life of me remove the bushing in the pinion casting boss.

I've managed so far to remove the circlip, the first small bushing with rubber 'o' ring inside, but can't shift the next metal bush?

I'm struggling to even get it to show any signs of movement?

Any ideas on how to persuade it to shift?

Also, where to obtain shims, lock washers and track rod end cups?

Thanks in anticipation,

Regards,

Phil.
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PostPost by: RichardHawkins » Wed Jun 28, 2017 7:47 pm

Phillip,

I can't help with the bush problem, but I bought shims and lock washers from Moss. The rack is aTriumph component so I guess that Moss or Rimmer Brothers can supply the other parts also. They might be even be able to help with advice.

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PostPost by: types26/36 » Wed Jun 28, 2017 8:23 pm

I just stripped and checked my two seater S2 rack and had no problem getting the pinion out (although it has a +2 pinion......6 teeth) which makes the steering very light......should have a 7 tooth but that is another story :roll:
Anyway have a read over this thread which may help you:
elan-archive-f16/stuck-rack-pinion-t6339.html
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PostPost by: l10tus » Thu Jun 29, 2017 5:42 pm

Rich, Brian,

Thanks for the replies.

The threads attached go some way to helping, but I think the guy using the "pickle fork?" is getting mixed up with the rack bushings and not the pinion ones ?

It would have been too easy for the manufacturers to make the blanked-off boss in the opposite end, an access to punch the pinion out - wouldn't it! (Or is that how the professionals do it without telling?)

At present I'm soaking it in WD40, hoping that may loosen it up enough to assist with the removal.

I used blowtorch heat to get the smaller bush out, but that dosn't seem to help with the lower, larger one.

Once warmed up, I ended up whacking (it upside down) against a timber joist to dislodge the first section.

I'll continue and update the thread when(hopefully) it's out!

Many thanks,

Phil.
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PostPost by: types26/36 » Thu Jun 29, 2017 6:47 pm

l10tus wrote:Rich, Brian,
The threads attached go some way to helping, but I think the guy using the "pickle fork?" is getting mixed up with the rack bushings and not the pinion ones ?Phil.

Phil, I dont think he is talking about the rack bush as he specifically mentions the pinion, I read it a few times and I quote:
"Well I finally got that stuck pinion out of the rack. No amount of gentle
coaxing was going to work. I ended up using a pickle fork (not sure if
that's the official name for it) and some open ended wrenches to force it
out. The open end wrench was just a hair larger than the bushing and was
held in place against the pinion housing. I attached the flexible steering
knuckle and wedged the pickle fork between the wrench and the knuckle. As I
hit the pickle fork the pinion and bushings slid up into the open ended
wrench
. The wrench protected the housing. Sure enough the bushings were
corroded. The rack housing wasn't damaged by this operation so I thought
I'd pass it along.

I think what he is saying is that he attached the steering coupling and levered it against an open ended spanner
until the pinion came out but I agree, its a little unclear but maybe one of our American cousins could read it and clarify as I believe it was an American poster.
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PostPost by: l10tus » Thu Jun 29, 2017 8:33 pm

Oh, ok. Thanks.

But he also mentions using a line reamer after drifting the inner bushing out.

I can only imagine how I'm going to be able to drift that out of a blind hole??

Never the less i enquired about a replacement rack and pinion parts from the usual suspects and found the rack is unobtainable.

Pinions are available @ ?60.

Wonder how much is "reconditioned" when this option is chosen??
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PostPost by: types26/36 » Fri Jun 30, 2017 6:05 am

l10tus wrote:
Pinions are available @ ?60.


Phil, I thought pinions were no longer available, who are selling them?
Thanks
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PostPost by: fatboyoz » Fri Jun 30, 2017 6:34 am

Brian,
Lotus Marques in Melbourne (Australia) sells them.
http://lotusmarques.com/parts/catalogue ... rack-parts
Cheers,
Colin.


types26/36 wrote:
l10tus wrote:
Pinions are available @ ?60.


Phil, I thought pinions were no longer available, who are selling them?
Thanks
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PostPost by: rgh0 » Fri Jun 30, 2017 11:29 am

The easiest way to get a bush out of a blind hole is to pack it with grease and fit a rod into the bush that is a close fit. The hit the rod with a hammer and the hydraulic pressure forces the bush out.

Same method to remove a pilot bearing or bush from the end of the crank.

cheers
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PostPost by: Chancer » Fri Jun 30, 2017 11:37 am

Yup, works a treat even with a needle roller bearing crank.

I have a set of surgical looking "pilot bearing" removers but the rod and grease always works.

Back in the depths of my memory I remember always struggling to remove the bearing outers from BLMC Mini/11/1300 FWD transmission idler gears, that was in the days before angle and die grinders were available to bodgers like me who didnt even have the electricity to power them, everything was butchered out with a selection of hammers and chisels, some quite surgical.
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PostPost by: l10tus » Fri Jun 30, 2017 4:16 pm

Rohan,

Thanks for the reply and words of wisdom.

I like the hydraulic removal method idea - but I'm.not sure how to actually it carry out?

The problem is obviously the pinion is still in.

Otherwise I could use the central hole that this pokes through, in order to fill with grease.

Is there another way?

Regs,

Phil.
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PostPost by: Elanman99 » Fri Jun 30, 2017 9:06 pm

Phil

I'm confused as to exactly what is stuck.

One understanding is that you are now trying to remove the pinion and the lower bush?

It seems you have managed to remove the top bush with 'O' ring etc but the pinion is still jammed in place. Does the pinion rotate though?

Alternatively if you already have the pinion out then its only the bottom bush you want to extract. The hydraulic method should work and you can use the existing pinion as the 'piston'. I have a vague feeling though that the casting that the bush is pressed into actually has a through hole which is blanked off with a steel disk put in the bore before the bush, do it should form a good enough seal against the hydraulic pressure.

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PostPost by: NickD » Fri Jun 30, 2017 10:55 pm

Regarding Wonder how much is "reconditioned" when this option is chosen??, I noticed that SJS show the following under Hints & Tips on their reconditioned Elan racks:

"With the age of these units we have found that a very large propotion require new major components during reconditioning. As a result of this, I have made it policy, that all our reconditioned racks will have a new rack bar and pinion fitted. Cheaper options will not have this."
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PostPost by: l10tus » Sat Jul 01, 2017 7:57 am

Thread update as promised.

Last night I managed to remove the pinion by applying gentle heat to the stuck bushing, i played the flame around the aluminium boss then used a 16mm deep socket to tap the bush home tight against the pinion.
I believe this had the effect of breaking the seal of corrosion and enabled me(after applying a little more heat) to hit it against a piece of timber again and force the bushing out.

What an awkward job !

That was the good news.

The not so good news was then discovered!

Rack is worn past re- use, pinion is worse.

This will need both renewing.

Anybody know where to obtain said items?

It may be just cheaper to do the refurb myself, as I checked the cost of a new rack - its ?275 plus vat.

Glad I ripped it down though - this was a disaster waiting to happen!

Regs,

Phil.
20170630_213314.jpg and
20170630_213223.jpg and
20170630_213314.jpg and
Attachments
20170630_213235.jpg and
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PostPost by: l10tus » Sat Jul 01, 2017 8:07 am

Fair play to SJS ! - I can see why their statement makes sense.

Just wondering if the Triumph steering racks offered by Moss, Rimmers, etc for ?175 - include a new rack at that price? The lads on the counter sales team didn't seem to know?
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