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i am installing a remanufactured rack from fcp. i think the replacement i received was a different model than what came off the car, however i don't know the exact type. the original rack was secured by two U bolts, the replacement by 1 U bolt (right side) and 2 long bolts (left side) that thread directly into the rack.
i thought i was done with this dirty job and went to attaching the last banjo bolt (forward-most) already starting to feel the satisfaction of my first rack replacement. it wouldn't fit. i am not familiar with 240s of earlier years, but mine has these metal hockey-stick looking things which contain the banjo bolts and attach to the flexible hose about 3-4" back. the rear most line goes on fine as there is plenty of space behind it for the horizontal section of the hockey stick. the front one is a different story. the horizontal section is blocked by either the rear-most hockey stick, the motor mount to the right, or the rack itself to the left. i can almost squeeze it in right next to the motor mount, but when i get about half way through tightening it down, the hockey stick binds on the mount. putting the forward-most banjo bolt on first doesn't leave enough space to get the rear banjo bolt in. of course i didn't take a picture before i started :(
do i need to flip one of these banjo bolt hockey sticks upside down? that doesn't seem like it would work. i thought maybe the entire rack was too far to the passenger side, but the bolts that secure the rack on the driver side line up with the holes in the crossmember? are there issues with these banjo bolts when going from CAM to ZF or the opposite? also notable, i have all the bolts securing the rack to the cross member fairly tight, i just haven't given them their final torque yet, so i don't think its a problem with it being out of alignment.
i am so so close! please help!
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