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Install from hell, Abbott steering rack brace,
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Posted by Dean (more from Dean) on Sat, 14 Apr 2001 21:22:30 Share Post by Email
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I finally got the rack brace installed after two weekends and two days of difficult work. My vehicle is a bit wierd, nothing wrong with the Abbott hardware.

My 95SET has the '94 style large cast aluminum rack body. It seems to be offset a bit around 5/32" to 5/16" to the left side of the vehicle. The smooth OD where the rubber bushing seats has rased locating ribs of some sort to each side. So the right most rib intruded around 1/8" into the aluminum rack brace clamp. I spone with Neal at Abbott at length. They have never hear of this issue before.

So I used a high speed burr in my Dremel to remove the rib from the top. So the rib that was below the horizon was left. I relieved the edge of the clamp ID below the horizon, and that settled the interference problem.

Now outer clamp half is a beast to get into location. But that is an other issue. It is like a chinese puzzle on steriods. Yes, it takes lots of force and determination.

Now the fun part. The lower fastener is a stud, the upper is a bolt. The stud is there, but you can hardly see any of it. The nut that was on it did not need to engage very far, but the Abbott special shank nut engages down to nearly the bottom of the stud, and engages about 3/4" of thread.

I could not see it, but the threads on the stud, just past where the orginal nut seated, were bad. I spent hours chasing those thread before I could get the Abbott fastener to run down the required depth. All of that with the clamp halves shifted to one side to be out of the way. I was glad to have my metric tap and die set available for the 8x1.25mm threads.

So the steering does seem to be tighter. It will take a few days of my regular routine to evaluate.

So I don't expect that others would have any problems like this. Most folks have the steel smaller steering rack body and this situation would not be possible then anyways.

Was it worth it? I guess. My arms and hands are torn up. But the job is done. Don't let this discourage you from this product. It is just a one-off horror storey and I need to post for everyones entertainment.

We had a perfect day today, but in typical Kansas style, were are getting severe storms now, and have a tornado watch.

Have a great weekend...


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