Doing a manual rack conversion in AE86

[4000GT]

So I have a PS rack now, and are looking for a manual rack, does anyone know which other models racks will work? DX obviously... others? Just want to make it easier to find one.

Andrew

[turbotoy]

ae-71
aw11

[4000GT]

Oh really AW11? Nice... tons of those around.

[TA22 1MZ]

I think you'll find the AW11 will be narrower than AE86. You need KE70 or AE7. The D bush on the power steering rack is different to the manual rack also

[4000GT]

Yeah was just going to solid mount it with an alloy spacer.

[TA22 1MZ]

So what are you doing with your PS rack??

[4000GT]

Probably sell it once I get a manual one, or keep it as a spare. It needs new dust boots, but otherwise seems ok.

[TA22 1MZ]

freight would make it a non worthwhile purchase for me unfortunately

[4000GT]

Yeah likely, I dont mind paying freight here for anyone selling a manual rack that fits...

[4000GT]

Im still a little green on the part interchangability, seems like you can use the AW11 with the AE86 tie rods, but need an MA70 steering column. If the KE70 / AE86 manual rack bolts in, can the existing AE85 power steer column be used or do I need a manual column too?

[TA22 1MZ]

I've got a KE70 rack in good condition. How about a swap? We'd just have to fing out about freight.

[4000GT]

Yeah could do, only issue is I need to find a manual steering column to match as the PS one I have wont fit from what I have read I wouldnt want to swap till I know I have a complete solution as a can just run PS if worst comes to worst. .

[Hen]

From my experience, AE86 and KE70 manual racks are interchangable. But the KE70 rack has one less tooth and 10mm less throw (so slightly less lock).

And from a friend who did a PS to manual steering conversion, there was also a difference in steering columns. I can't remember the details on this issue though, but it sounds like you're onto it anyway.

Hen

[DX20VT]

From my experience, AE86 and KE70 manual racks are interchangable. But the KE70 rack has one less tooth and 10mm less throw (so slightly less lock).

And from a friend who did a PS to manual steering conversion, there was also a difference in steering columns. I can't remember the details on this issue though, but it sounds like you're onto it anyway.

Hen

Interesting to know that too,

as I too have a p/steer rack, and are having trouble getting all the bits to make it all work,
pipes etc etc, and looked at the manual rack conversion,

and I have too read there is a difference, but cant work out what it is???

matt

[The Real Roadrunner]

The difference with the column is the short shaft in the end with the spline on it, The PS version is about 40mm or so shorter to accomodate the valve block ontop of the rack. the AE71 and AE86 parts do interchange as thats what i did.

The D bush on the bodies are identical but the round one is different as the OD of the PS version is alot bigger, about 50mm compared to the non PS being around 35mm.

The Xmembers are different also as the mounts are in slightly different positions due to the overall lengths of the bodies being different. its easiest to just swap the whole Xmember if you are using stock components.

To go from manual to PS i had to do the following

1 unbolt manual Xmember and rack and bolt in PS Xmember and rack
2 heat lower section of column to soften the rubber and pull out the splined section, while still warm i pushed in the shorter PS version.
3 hook up PS lines but in my case these were custom made from -6 teflon braid and fittings (for the high pressure line) as it was a simple and reliable but expensive sloution.
4 mount resivour and cooler
5 pleed system and adjust toe angles to suit.

The PS to manual conversion will be exactly the same but instead of shortening the column you fit the lengthened version.

cheers
linden