When I did the final inspection before removing the old steering rack tonight, I removed the belly pan, climbed underneath and had the wife saw on the steering wheel for me. Er, um, well, I found the problem was that the U-bolts that hold the rack to the cross member were loose... VERY LOOSE! The rack was moving nearly 1/4 of an inch side to side, ergo steering slop. I tightened up the 13mm headed nuts on the U-bolts after centering the rack and all slop disappeared!

I hope my new-found shame will prevent someone else from buying a rebuilt rack they didn't need in the first place! I have to assume that the new U-bolts that come with a rebuilt rack give over time and loosen up a bit, so perhaps following a rack replacement rechecking the nut torque a few months later might be a really good idea! Yes, the rack itself is fine.

jorrell
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92 245 250K miles, IPD'd to the hilt, 06 XC70, 00 Eclipse custom Turbo setup...currently taking names and kicking reputations!

As far as I know, there are NO adjustments for endplay or preload available on the ZF racks. The Cam racks could be adjusted including a balancing adjustment for evening the force required in either directions, but not for the ZF. What a shame. Remember when steering gearboxes had those little screw and locknut affairs on top? That was easy....and some years ago!

DS

The '92 245 I used to own had the exact symptoms you are describing, which were cured completely with the replacement of the lower steering u-joint. The difference was truly night and day once it was replaced. As you mention, it was particularly hair-raising to drive on our crested highways, some of which were undergoing resurfacing at the time. It felt like bad struts and bad tie rod ends at the same time.

Good luck!