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ZF Steering Rack mounting hardware

posted by  shaka on  Thu Jan 10 17:53 CST 2013
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last visit: Sun Nov 24 12:12 CST 2013
[RELATED]

I removed the power steering rack today on my 1983 242DL to replace it with a rack from a 1990 245. I discovered that the old unit is mounted to the body with two "U" bolt type brackets. The replacement unit which is marked "ZF" appears to mount with a "U" bolt at the passenger side end and two bolts which mount through the frame and thread into the rack. I only have a Haynes manual and thee is no mention of the diference between these two types of racks. The tie rods and hoses seem to fit OK as does the steering shaft. When I picked up the used ZF rack it did not come with any mounting hardware. My question is what are the lengths and thread sizes of the two mounting bolts that hold the drivers side of the rack to the frame? Does anyone have a photo of how the ZF racks mount? Is there anything else I am missing. The passenger side seems to mount fine with the "U" bolt from the original rack? Thanks for any help!
--
Dave Kenney North of Lake Superior 1983 305,000Km








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    ZF Steering Rack mounting hardware

    uid 27's pic
    posted by  Art Benstein on  Thu Jan 10 18:00 CST 2013
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    last visit: Fri Oct 17 20:10 CST 2014
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    Hi Dave,

    Here's what the ZF in my 84 had to mount it. Find more at http://cleanflametrap.com/oilpan/



    Also, I should have some pics of a ZF rack swap done on an 89, if that might help. Let me know.


    --
    Art Benstein near Baltimore

    A group of chess enthusiasts checked into a hotel and were standing in the lobby discussing their recent tournament victories. After about an hour, the manager came out of his office and asked them to disperse. "But why?" they asked, as they moved away. "Because," he said, "I can't stand chess nuts boasting in an open foyer."








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      ZF Steering Rack mounting hardware

      posted by  shaka on  Thu Jan 10 18:13 CST 2013
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      last visit: Sun Nov 24 12:12 CST 2013
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      Art, Wow that was fast! Thank you for the photo and the link! I think the bolts I am looking for are the two long ones at the lower right. Yes anything else that would give me some guidance appreciated. I guess you have no knowledge of the size of the two bolts ? Based on the photo I should be able to determine the length roughly by comparing to the "U" clamp. Very much appreciated.
      --
      Dave Kenney North of Lake Superior 1983 305,000Km








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        ZF Steering Rack mounting hardware

        posted by  Volvo From Heck on  Thu Jan 10 23:17 CST 2013
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        last visit: Mon Oct 13 20:56 CST 2014
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        The bolts should have an 8mm shank and usually a 13mm head. I don't recall the thread count but it will be the coarser of the two available---same thread as the "U" bolt--take one of the U bolt nuts to the hardware store for checking purposes--Dave








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          ZF Steering Rack mounting hardware

          uid 27's pic
          posted by  Art Benstein on  Fri Jan 11 03:34 CST 2013
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          last visit: Fri Oct 17 20:10 CST 2014
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          I can confirm it is standard M8 hardware (1.25mm thread pitch) but getting the length might need you to bring a hunk of wire and a tape measure to the task if not a guess from the photo. I thought it would have been the U-bolt and saddle that was the challenge. This is what Jorgen sent me for hardware on a CAM rack replacement:




          --
          Art Benstein near Baltimore

          The roundest knight at King Arthur's round table was Sir Cumference.








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            ZF Steering Rack mounting hardware

            posted by  shaka on  Fri Jan 11 07:48 CST 2013
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            last visit: Sun Nov 24 12:12 CST 2013
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            Art and Heck, Thanks once again. I determined they are M8 bolts and about 2 1/2" long. Is that about right. As Heck mentioned the same thread size as the "U" Bolt so I am good to go on that count. I plan on buying a few bolts about that long and maybe a bit longer as well and possibly use washers to fine tune. The other "U" bolt and saddle end fit fine. My biggest worry now is the U joint steering shaft connection to the rack shaft. I can get the two spines started together but they won't go together completely enough to get the clinch bolt through.
            --
            Dave Kenney North of Lake Superior 1983 305,000Km








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              ZF Steering Rack mounting hardware

              posted by  Volvo From Heck on  Fri Jan 11 09:21 CST 2013
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              last visit: Mon Oct 13 20:56 CST 2014
              [RELATED]

              If I remember correctly there is a flattened area on the rack input shaft where the pinch bolt can pass. The joint has to be aligned so the passthrough is parallel to the flat. If you have the joint aligned in such a way but it does not extend far enough to reach the flat you can loosen the pinch bolt where the joint attaches to the shaft and slide the joint down as needed. The same holds true for the upper joint attached to the column "stub". While the shaft is not attached to the rack this would be a good time to check the range of motion of both the upper and lower joints--they can often develop a "hitch" in the motion at the center position. -- Dave








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                ZF Steering Rack mounting hardware

                posted by  shaka on  Fri Jan 11 09:49 CST 2013
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                last visit: Sun Nov 24 12:12 CST 2013
                [RELATED]

                Thanks. I am aware that the flat on the rack shaft is to allow the bolt to pass but it still is a struggle. I will try to clean both shafts and look for burrs or damage.
                --
                Dave Kenney North of Lake Superior 1983 305,000Km








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                  ZF Steering Rack mounting hardware

                  posted by  shaka on  Sun Jan 13 08:47 CST 2013
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                  last visit: Sun Nov 24 12:12 CST 2013
                  [RELATED]

                  I bought 2 M8X60MM bolts and they seem to be very close to what I needed. Thanks for all the help.
                  --
                  Dave Kenney North of Lake Superior 1983 305,000Km







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