Just in case others are interesting in how to get the steering box re-assembled...
some photos...
Needed to reinstall all the parts from the steering box. The process (that worked) went something like this...
a) Inserted the lower bearing guide - lots of grease to make it go in easier. When it stuck I rocked it from above and below (through the other openings) to keep it moving.
b) Put grease on top of the lower bearing guide and dropped in the 14 bearings. Positioned the bearings around the outside using a BIC pen case.
c) Put the upper part of the bottom bearing in place... bearings need to be in grease and positioned around the outside.
d) Assembled the upper bearing on the bench. 14 bearings again and lots of grease.
e) Placed the upper bearing on the Pinion and kept pressure on it to prevent the bearings from falling out.
f) Inserted the rack rod into the steering tube from the drivers side, made sure gear teeth were visible in the steering box through the pinion opening.
g) Inserted the pinion (and bearing) into the steering box, rotating anticlockwise to get the pinion gears past the rack rod teeth. Needed to rotate the rack rod slightly to let the pinion in (teeth engaging).
h) Once the pinion is in, install the gasket, skim(s), and pinion cover (with the rubber/plastic seal) can be re-installed.
Steering box parts.jpgLower Bottow race guide.jpgGrease and bearings at bottom of steering box.jpgFull bottom bearing race installed.jpgSteering rack rod installed.jpgPinion with upper bearing race installed.jpg
I am refurbishing the steering rack as part of a plan to find and fix some steering vibration sources (in preparation for other secret squirrel project). As part of this I replaced the stock plastic tie rod end cups (dimpled things) with brass ones made for a Lotus steering rack of the same vintage. As it turned out mine were not worn much.
Plastic and Brass strack rod end cup.jpg
I also wanted to replace the stock nylon (plastic) bushing at the other end of the rack from the steering box - on the passenger side. This bushing holds the rack rod in the center of the steering tube. While it looks in shape the plastic was degrading. The brass bushing is longer than the stock plastic bushing and gives a very solid feel to the passenger side of the rack. Pictures are of...
a) Stock nylon bushing
b) Brass bushing sized up to the rack location of the nylon bushing
c) Brass bushing installed on the RH side of the rack in place of a nylon bushing
d) Rack rod installed into box from the driver's side
e) Rack rod installed through new brass bushing
Original RH rack bushing.jpgBrass bushing sizing.jpgBrass bushing mounted.jpgRack rod installed through brass RH bushing.jpg
Jeff