*HOW TO* Install a quickrack with engine in situ

[trackdaynova]

Tools needed:
Flat blade screwdriver
13mm socket
13mm rachet spanner
a bit of patience
22mm spanner
18mm spanner
33mm spanner

Then it's off with the standard steering rack, which was a bit fiddly with everything in situ, but it's do'able, so I've removed my rack as I've ordered a quick rack from Harry Hockly Motorsport, which will be here tomorrow.

One with a couple of pics, and a mini 'How-To' on how to remove the rack with engine in situ.

But if anyone has ever bought a quick rack kit and built it into their own rack, please can you help me out (see below, after photos)

In a poxy single garage, you have to park on the pith in order to get enough space on the nearside, off with the wheels, and on stands
http://i136.photobucket.com/albums/q161/neocapture/nc0721.jpg

Strut brace and filter offski
http://i136.photobucket.com/albums/q161/neocapture/nc0722.jpg

Then I did the trackrod ends, just undone the nuts for now
http://i136.photobucket.com/albums/q161/neocapture/nc0723.jpg

Then went under the car and done two of the four 13mm nuts
http://i136.photobucket.com/albums/q161/neocapture/nc0724.jpg

Then the top ones, this one is fine, the other one (behind gear linkage holder) is a bugger
http://i136.photobucket.com/albums/q161/neocapture/nc0725.jpg

The knock out the rod ends
http://i136.photobucket.com/albums/q161/neocapture/nc0726.jpg

Inside the car, remove the 13mm bolt
http://i136.photobucket.com/albums/q161/neocapture/nc0727.jpg

Upon removal, to get it out the nearside wheel arch, above the gearbox, you have to rotate the rack 45degrees so the bit inside the car is pointing down
http://i136.photobucket.com/albums/q161/neocapture/nc0728.jpg

Standard rack off, all stripped down, boots off, rod ends off
http://i136.photobucket.com/albums/q161/neocapture/nc0729.jpg

[trackdaynova]

Rackless bay
http://i136.photobucket.com/albums/q161/neocapture/nc0730.jpg

Rack teeth
http://i136.photobucket.com/albums/q161/neocapture/nc0732.jpg

this is the 22mm bolt you have to remove to install the quickrack kit
http://i136.photobucket.com/albums/q161/neocapture/nc0731.jpg

So off with the big 22mm preload nut
http://i136.photobucket.com/albums/q161/neocapture/nc0735.jpg

becareful as the spring inside will still be loaded
http://i136.photobucket.com/albums/q161/neocapture/nc0736.jpg

remove the spring, to find the rack positioner
http://i136.photobucket.com/albums/q161/neocapture/nc0737.jpg

remove that, with a magnet
http://i136.photobucket.com/albums/q161/neocapture/nc0738.jpg

turn rack 45° to expose bearing cover, jap in a screwdriver in the edge
http://i136.photobucket.com/albums/q161/neocapture/nc0739.jpg

prise the plastic cover off
http://i136.photobucket.com/albums/q161/neocapture/nc0740.jpg

[trackdaynova]

remove circlip, with a pair of circlip pliers
http://i136.photobucket.com/albums/q161/neocapture/nc0741.jpg


Greased up pinion out
http://i136.photobucket.com/albums/q161/neocapture/nc0743.jpg


Old & New
http://i136.photobucket.com/albums/q161/neocapture/nc0746.jpg


Part number for Harry Hockly Motorsport one, should anyone want to buy one £132 delivered
http://i136.photobucket.com/albums/q161/neocapture/nc0747.jpg


The original part number is a NACHI make, and number 6203z
http://i136.photobucket.com/albums/q161/neocapture/nc0750.jpg
http://i136.photobucket.com/albums/q161/neocapture/nc0751.jpg
Not a great deal of play, but as I've been advised, its 20 years old and has done alot of work so must be a good thing replacing it
The new one is SKF make, with the part number 6203-2z/c3 which is identical size, but it has closed both sides, rather than one side having exposed ball bearings
http://i136.photobucket.com/albums/q161/neocapture/nc0752.jpg
http://i136.photobucket.com/albums/q161/neocapture/nc0753.jpg

[trackdaynova]

You'll need a 33mm spanner, and an 18mm spanner probably with an extra bar to give you the leverage you'll need to bend the tab out
http://i136.photobucket.com/albums/q161/neocapture/nc0754.jpg

Unscrew them
http://i136.photobucket.com/albums/q161/neocapture/nc0755.jpg

Old & New Rack
http://i136.photobucket.com/albums/q161/neocapture/nc0756.jpg

Casing which I'm going to replace now anyway
http://i136.photobucket.com/albums/q161/neocapture/nc0757.jpg

New bearing on pinion
http://i136.photobucket.com/albums/q161/neocapture/nc0758.jpg

New bearing on pinion
http://i136.photobucket.com/albums/q161/neocapture/nc0759.jpg

Closed bearing this time
http://i136.photobucket.com/albums/q161/neocapture/nc0760.jpg


Refitting is the reverse of removal :thumb:

[Graeme]

Very helpful Olly and I thought all your rep was for giving Stuart sexual favours

[kevster]

spot on thanks dude

[scott.parker]

Ah ha! Found it again, will be needing this after I'm back off holiday!
Nice one Olly.

Scott

[Clony3k]

Thanks for the guide! :)

[markmcgivern]

just a quick one, iver got my new rack and pinion on order from quaife, the bearing that you put on, did you get one supplied from HH or is that a seperate purchase?

[Iain]

You can get the bearing from a separate supplier using the reference mentioned above

[AndrewC]

Really useful "How to" thanks

[Hobbit]

How much wiggle room do you need when pulling the rack away from the firewall?

http://i125.photobucket.com/albums/p72/wiggardywoo/20150125_114312.jpg

Guess I have no chance with the downpipe in place. :(

[mowgli]

enough to get the input shaft to clear the bulkhead, so maybe 2"

[Hobbit]

Might be able to squeeze to 1.5 inches... bum.

[conza123]

Might be able to squeeze to 1.5 inches... bum.
I'm guessing u got a quick rack aswell as a alloy rad for your birthday

[mowgli]

You'll have to drop a couple of engine mounts off

[Hobbit]

Yes Conza. Nova hasn't had this much love since building it.

Dropping engine mounts in my garage will end in tears as my mounts are stupidly solid.

[Benn]

Has anyone managed to get the bearing off the shaft that goes into the car? As i couldn't at all.

[AndrewC]

Benn...if you are talking about the bearing on the pinion then apparently it is crimped in and you can't get it off to re use. The advice I had and followed was to buy a new bearing. I got mine from Simply Bearings in Lancs. see my build thread if needed (about reply 73 I think)

[Benn]

I have a new bearing. Its the collar under the bearing i meant.

[Iain]

Having looked at your picture it looks like you can't replace it. However on the quickrack pinion there's no pressed/welded/machined lip or whatever it is, so you could potentially look to cut/machine that off (although I wouldn't fancy hacking the pinion about myself)

[Hobbit]

Was a ball ache. Guide says remove collar with magnet. It took lots of bashing and swearing to remove it when we did mine.

[Benn]

Having looked at your picture it looks like you can't replace it. However on the quickrack pinion there's no pressed/welded/machined lip or whatever it is, so you could potentially look to cut/machine that off (although I wouldn't fancy hacking the pinion about myself)

I couldnt move it at all, with a press. Then hammer and chisel.
I'm guessing the quick rack one is just a press fit.


Was a ball ache. Guide says remove collar with magnet. It took lots of bashing and swearing to remove it when we did mine.

What? No chance a magnet would move it, a 3ton press wouldn't move it.

[CorsaBBoomer]

No collar on the quick rack (did it a few weeks ago)
I was also trying to get it off the original to have a spare with new bearing but no luck either getting it off... I heated it up o the point that the grease ran out of the bearing...
But I can try tonight to see after some cutting and let you know what it looks like

[CorsaBBoomer]

Can't seem to get it off without damaging the pinion. My guess it's heat schrinked or something... :wtf:

[Iain]

So to conclude the bearing isn't a replaceable item on a standard rack!