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Go Back   Madabout Kitcars Forum > Mad Build Area > Marlin 5exi builds

Marlin 5exi builds Calling all you sexi builders....sorry 5exi builders, show us your progress.

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  #1  
Old 10th January 2012, 18:48
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Default Steering rack and UJ

Hi everyone.

I needed to get my rack inner tie rod extended as it was too short on the passenger side. So sent it off to get extended. Whilst there, they noticed about 8mm of play at the pinion. Not dangerous they said, but will feel a lot of play. So getting totally reconditioned now.

Whist the rack was off, I decided to investigate the rack pinion and uj splines. Not looked at them since building the car at the beginning. But remember some old posts saying the teeth in the UJ having different number of teeth. What I came across shocked me.

The column and UJ was off a Rover 220 turbo 1993. Going by the splines in the UJ, about 19 teeth and about 16mm in diameter. I say about, as it is badly worn both ends!
The Rack is off a MG Metro (rare as hens teeth now). Wider track than the standard Metro and a 17 teeth spline.
Rack end of UJ


Column end of UJ


Rusty end = Rack connection



So looking at possibly getting a forged one made up. Hoping a MGF UJ end will fit the rack. Going to try tomorrow so the right fitment can be identifed.
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  #2  
Old 11th January 2012, 16:56
mike joiner mike joiner is offline
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Very keen to see the outcome of this as so far it is the only thing on the car that I am not very happy with.I must admit that I have still got a lot of work to do so there is plenty of time for more issues to crop up .
Mike
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  #3  
Old 11th January 2012, 20:21
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Hi Mike.

If it's easier to get to on yours can you measure count the following?

Steering rack pinion teeth and diameter. Mine has 17 teeth and about 15-16mm in diameter.

Steering UJ number of teeth and diameters. Mine has, as far as I could tell around 19. But other half made it around 28. But was very worn both ends. 28 makes more sense as follows.

Count column teeth and diameter. Mine has 29 teeth and around 15-16mm. Pictures...

Flat section as well.




I'm looking at getting the correct UJ made for both rack and column. So if yours is the same as mine, I can get another ordered. If it's possible.
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Old 11th January 2012, 20:23
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Oh, I feel slightly guilty now as I found a solution for this about April last year when I lost control of my car putting it on a trailer.

Anyway what I have done is SPLIT the UJ & SWAPPED the rack end of the UJ for one off of a Metro, squeeze them back together & your sorted.

So basically you have a Metro UJ on the rack end & a 200 UJ on the column end. That way it is a direct, but tight, fit on the spline of the rack. I still use a nut & bolt to hold it on though, just in case.

Metro's are very difficult to find but I just took the column out of one in the scrapyard and then swapped over the UJ's once I got home in the garage.

Might be cheaper than a forged one:P

Hopefully that makes sense sorry its not best explained PM me if want more details.

Jono

p.s Sorry for not mentioning sooner

Last edited by JONORacing; 11th January 2012 at 20:30.. Reason: Got it wrong :P
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  #5  
Old 11th January 2012, 20:36
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Hi Jono.

How do the split apart and go back together. Don't suppose you have any photo's do you? Looking at my UJ above, it looks like it welded/pressed together in the centre.

Mine are very worn anyway. But don't think they will be too dear. Wait and see for a price.
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  #6  
Old 11th January 2012, 20:42
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I don't have any photos of doing it as it took 5 minutes and I didn't think.

Found some old bots taking pics now
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Old 11th January 2012, 20:48
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Update on my rack. It was in a terrible stae apparently. 8mm play on pinion together with slightly seized joints and collapsed bearing.

Also noticed Mike did what you did Jono. But not how it's done.

http://www.madabout-kitcars.com/foru...niversal+joint
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Old 11th January 2012, 21:36
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Please note this is for guidance only. I am not liable for anyone that uses this method and it then fails, breaks or damages anything :P

This shows the end result, quite easy really.
http://www.flickr.com/photos/5862584...n/photostream/

This shows the old metro extention piece missing the rack end off the UJ.
http://www.flickr.com/photos/5862584...n/photostream/

The next two pics help to show how to do it
http://www.flickr.com/photos/5862584...n/photostream/
http://www.flickr.com/photos/5862584...n/photostream/

OK, The UJ is pressed together.

#There are some bronze colour caps which shown with green arrow need removing. I used a plunt punch and hammer.

#Once the bronze bits are protruding enough to get a grip, clamp in a vice gently and pull the the rest away from it leaving the bronze cap in the vice. Repeat for the other side.

#NOTE: the black rubber bits are important so take care not to loose them :P. Once both bronze bits are off, wiggle both bits until they separate, it is a little fidderly but not too bad.

#Once the old 200 rack clamp is off put the metro one in its place making sure the black rubbers are in place FIRST. Then push the bronze bit back through the wholes with fingers and place in vice.

#ENSURE IT IS EVEN WHEN DOING UP THE VICE & PRESSING THEM BACK IN. You can do one at a time if easier.

Hopefully that helps to explain but I will do a video over the weekend and post it up on here which should help more.

ATB Jono

Last edited by JONORacing; 11th January 2012 at 21:41..
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  #9  
Old 11th January 2012, 21:54
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That's a great little right up there Jono.

Easy fix as well. Just need to make sure the second hand ends are not worn already like mine.

Was it just standard Metro?
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  #10  
Old 11th January 2012, 22:00
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Yeah complete standard Metro 100.

Took the whole column and sorted it out once got home. Had a spare floating about for ages but binned it when having a massive clear out.

Ebay has plenty for about 10-15.

ATB Jono.

I'm @ Autosport tomorrow so will have a little look. Never know what you find up there.
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Old 12th January 2012, 17:08
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Looks like that is a far more cost effective method than getting the parts made from scratch, I can measure and count splines if you want just let me know if you went to go that route
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Old 13th January 2012, 05:24
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The guy is enquiring at the minute to see if the company has the right tooling to make it. I was told it probably won't be expensive. Something like about 30 made up and new. Got another 5exi owner interested as well.

He has the same setup as me. Mk2 200 column and UJ. Not sure if there's a difference with the mk3 200 ones.
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  #13  
Old 16th January 2012, 16:38
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Just found the Haynes manual for the mg turbo. It don't use a uj to connect to the rack.

http://totinus.free.fr/Mini/Autres/D...es/0718-10.pdf
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Old 16th January 2012, 17:08
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Do you know if this the same set up as on the metro 100? can not find manul so not sure.
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Old 16th January 2012, 19:57
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The metro 100 ones are like this from Jono's post above.

http://www.flickr.com/photos/5862584...n/photostream/

The MG metro and Metro 100 are so different in the way the steering is done.
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