If one is installing a rack and pinion by oneself with no help, what is a way to to work the lower u joint onto the rack pinion? I have the right side loosely installed (u bolt). It seems like you really need three hands--one hand for the hammer to tap the ears of the u joint down onto the pinion; one hand to hold the u joint still while tapping, and one hand to support the rack unit. Plus I have a screw driver wedged into the seam of the u joint to keep it open and it wants to keep falling out. Has anyone ever just screwed a screw into the seam to keep it open so two hands could place the u joint onto the pinion cleanly and then use one hand for a hammer and one hand to counter hold the steering unit? Hindsight is 20/20, but if I ever do this again, replacing the u joint with a new one is definitely the way to go. Not an option for me right now though.

Re: the copper washers for the high pressure and return line banjos on the steering unit: the only washers that were on the unit were between the bolt head and the top of the banjo, none between the banjo and the rack orifice.
The washers were very narrow, and very brittle, old. this was one source of fluid leaking. I bought 4 new copper washers at a hydraulic supply business that fit the banjo bolts perfectly, but they are about 4 times wider, ie measurement from inside diameter to outside diameter. Since everything looks like a flush fit, should not be an issue. Manufacturer of unit says warranty voided if any type of thread sealant is used to improve seal of copper washers.


Any comments, suggestions, greatly appreciated.

What lucid said about moving the entire u-joint upward so the rack can get secured first----and---there is no need for any sealant at the banjo bolts. -- Dave

thanks for the info. The secret is being able to tap the whole u joint up, and then tap it back down. It worked very well. John

"Has anyone ever just screwed a screw into the seam to keep it open...?"

Yes, Ive used tapered steel wood screws like that. It's best to open both ujoints, then working from below, drive the upper joint upward enough to let the section with the lower joint be swung aside out of the way.

After the rack is secured, the section is then swung back so the lower ujoint can be fitted onto the pinion shaft and the job finished up.


--
Bruce Young, '93 940-NA (current), 240s (one V8), 140s, 122s, since '63.