Included Logo Page

The Old CLUB4AG FORUM ARCHIVE

For reference only, all new posts and communications should be posted in the new forums at http://club4ag.com/forums

 
 

 

My Profile | Active Users | Member List | Search


Print  Email  Subscribe  RSS  Help
 AE86 Quaife QSR & Manual steering rack info.First  1 2 3 4 5 >  Last
Author Post
assassin10000
Teq



Offline

4959 posts [100%]
Northern CA

 AE86 Quaife QSR & Manual steering info. Reply  Edit


Alright, here's another one of my old(er) tech threads, along with some fresh(er) info at the bottom of the page.

~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

Quaife QSR - Installation & manual steering info:

----------------------------------------------------------------------


AE86 Corolla manual steering rack assembly.

Dissassembling a manual rack.
Note: LARGE 24" crescent wrench necessary (lock/retaining nut is 48mm/2" in)

When dissassembling just take it apart and keep everything in order, you don't need to remove the bottom bearing for the pinion gear unless you're replacing it.

Dissassembly:
1. Remove 2 locking nuts (#1 & 2)
2. Remove rack guide cap nut, tension spring, rack guide. (#2)
3. Remove pinion cap nut, pinion gear & top bearing. (#1 & 4)
4. Slide rack gear out of housing - ONLY take it out the drivers side, as pulling it out the passenger will 'score' the pass side end bushing/guide. (#3)

Be sure to clean out as much of the old grease as you can (I used several 3/8" extensions and a couple paper towels to clean out the inside of the rack) Also, make sure the 4 holes just before the end of of the rack housing on the passenger side are clear otherwise you may blow the steering rack boots up or suck them into the gears as it equalizes pressure from one side to the other when moving back and forth.


Dissassembled manual rack: top rack & pinion gear set is toyota factory, bottom rack and pinion is a Quaife Quick-Steering Rack gear kit. The one pictured is a modified Quaife QSR kit with 2 extra teeth cut for additional angle with a Battle Version #2 steering angle kit (if needed).

Manual rack pinion bearing removal
Note: installation is flipping gear opposite way to pull bearing down pinion gear shaft.

NOTE: Use molybdenium lithium based grease for reassembly - it came in a black 'peanut' size can from reibes/napa - kragen/shucks/checkers didn't carry it locally.

Apply grease before assembling to:
Rack gear teeth and lightly coat the back side of the gear tooth area.
Pinion bearings & gear (can be packed into pinion gear area, just dont want to fill the whole rack with grease)
Rack guide & spring as rack gear glides along/against it.

Reassembly.
1. Install rack gear, slide in from drivers side.
2. Install Pinion gear, top bearing and cap/tension nut.
When installing spin down pinion nut cap finger tight, then take a small screwdriver and by hand give a small tug to lightly 'snug' down the pinion gear and bearings - no more pressure than that is necessary, or wanted! It is supposed to be set with a inch lb torque wrench for preload but I've found that finger tight with a tiny snug sets it just as well as it was set from the factory (ie: enough to hold steady with no wobble but light enough it spins freely).
3. Install rack guide, spring and cap/tension nut.
I puchased a 3/4" (?) size bolt and 2 nuts from home cheapo that fit into the cap correctly so I could tighten down the cap/tension nut with ease. Snug down by hand & wrench until the rack gear/shaft has no lateral (forward/back & up/down) play, but moves left and right with no catching and/or binding.
4. Install locking nuts.

----------------------------------------------------------------------

For reference:

AE86 Corolla Manual steering intermediate shaft vs p/s intermediate shaft

AE86 Corolla Manual rack intermediate steering shaft installed
Note: due to low height of manual rack, the steering shaft was 'pulled' out farther than shown in picture.

If you do not have the manual rack intermediate steering shaft, you can take two p/s column's, cut the end off of one column at about 3.75" (3 3/4)" and weld it to the second for the extended reach.

AE86 Corolla Manual vs PS rack pinion shaft size
As can be seen in the picture, the p/s and manual rack pinion shafts are different sizes. Which means you cannot use the u-joint for the p/s on the manual rack or vice versa.

AE86 Corolla Manual (top) vs P/S (bottom) driver side brackets
I decided to go with the P/S bracket (bottom) as it is much stronger.

AE86 Corolla Manual Rack (center & right) vs P/S (left) pass side brackets
Note: the markings are around the areas that needed to be ground/widened to fit correctly on my originally P/S equipped vehicle. (may vary from vehicle to vehicle - not sure if it'll be necessary on anyone elses)

----------------------------------------------------------------------

Misc.

AE86 Corolla manual steering factory pinion gear vs. quaife qsr pinion gear (quaife left/lower, factory right/upper)

AE86 Corolla Manual vs P/S Rack

AE86 Corolla Manual rack installed.

----------------------------------------------------------------------

Link to a video of steering angle (provided by nimdivo)
http://home.comcast.net/~nimdivino/quaifeqsr.wmv

UPDATE: after spraying my inner fender area with some undercoat, to cover the area I hammered back to clear tires with ncrca's & 2.5 degrees caster I notice I AM rubbing on the inner unibody frame rail on both sides at full-lock with the p/s knuckles.

So, in other words. If you run p/s knuckles you won't need a BV kit or aftermarket (ueo/jic/etc) tie rod ends, as it wont help you get more angle. Or atleast without some super wide offset rims, or really far out there adj. control arms/ncrca's

UPDATE 2: just an FYI, aw11 rack housings are the same as the ae86, the only difference is the aw11 rack 'pinion' gear shaft is 1 inch longer and doesn't need the column extended as far as the ae86 rack & pinion gear. (NOTE: if you swap the quaife qsr into the aw11 rack it would be the exact same as an ae86 rack equiped with a QSR)

UPDATE 3: From my posts regarding manual rack/qsr on club4ag regarding column extension/adapters

--------------------------------------------------------------------------------

I just took a quick measurement, there's an extra 1 1/4" of shaft that should be inside the column extension.

Some quick math on the differences in ae86 manual rack column & intermediate shaft differences = 3.825" extension would be perfect. (just a hair under 3 53/64" which is the combined difference between the total lengths of the manual & p/s column and shafts.)

So if you were going to weld to the column/make and adapter: I'd just round it down to 3.75 - 3 3/4" for the extension if installing a quaife qsr/oem ae86 manual rack

Subtract 1" if using an aw11 manual rack.

--------------------------------------------------------------------------------

~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

UPDATE 11/15/07:

Parts necessary to convert to manual steering on an AE86; multiple choices/ways.

1. Steering rack.
A.) AE86 manual rack
B.) AW11 manual rack

Note: both will need to use AE86 inner & outer tie rod ends. The AW11 inner tie rods are too long, and the outers won't fit.

2. U-joint/Rag-joint between manual rack & steering column/intermediate shaft.
A.) AE86 manual rack u-joint
B.) AW11 manual rack u-joint

3. Passenger side brackets or adapters.
A.) AE86 OEM manual rack brackets with OEM/Poly manual rack bushings.
B.) Homemade manual rack brackets with OEM/Poly manual rack bushings.
C.) T3 Manual rack conversion bushings, utilizing the power steering rack brackets.

Tip: the power steering drivers side bracket is stronger than the manual steering version, so I recommend using the drivers side power bracket.

4. Intermediate shaft or steering column extension.
A.) AE86 manual steering column & intermediate shaft.
B.) AE86 power steering column, weld on column extension. So that the intermediate shaft is able to reach the steering rack to connect them with the U-joint.
(Approx 3.5" length extension if using an AE86 manual rack, 2.5" for AW11 manual racks.
NOTE: This is going off of measurements on the AE86 rack, and 3rd party information on the AW11 rack. AS I have been told the steering rack splined shaft is 1" longer on the AW11 manual rack, than the AE86 rack.
IF you're going to weld an extension on, be SURE to take measurements and verify it for yourself!!!)

C.) AE86 power steering column & MKIII/MK3 Supra Intermediate shaft.

_________________________________________________________
UPDATE 11-18-07

Just to confirm it, I went to the junkyard today and pulled an MKIII/MK3 Supra intermediate shaft. It will work VERY well for an AE86 manual steering swap. Matter a fact, I'm going to change it out with my AE86 one as it will give me a stronger setup.

The reason being using an AE86 manual intermediate shaft with the power column leaves you with only 1/2-1" of insertion into the column... with the MKIII Supra one I'll have 2-2.5". Making it a much stronger connection.


___________________________________________________________

Update 11/18/08

What I 'believe' are the known versions of the QSR and the differences.

Version 1: Rack gear bottomed out on pinion gear before tie rods hit due to not enough teeth cut into rack gear.
(The reason Taka Aono didn't use it on his auto-x 86 - IIRC)
Version 2: Correct length for stock replacement, IE: inner tie rods bottomed out against the rack like stock. Good for racing/autox/grip but not still did not have enough teeth cut for additional angle spacers/tie rods for the drift crowd.
Version 3: Ability to use spacers/aftermarket tie rods. Has the extra teeth necessary.

(And then there is also a prototype/modifed version 2 with extra extra teeth, I might be the only one with it according to Long/xXRidgeRacerXx who was the original person to make the effort to get Version 2 & 3)
___________________________________________________________

Anyone got any other suggestions, tips or answers?

Andrew

Modified by assassin10000 at 1:30 AM 11/19/2008



MidTenn Drifter
Cone Pilot



Offline

1571 posts [100%]
Murfreesboro TN

 Re: AE86 Quaife QSR & Manual steering info. (assassin10000) » Reply  Edit


Great write up once again. Added to the Tech reference. I'd be interested seeing back up information on the MKIII Supra intermediate shaft in the PS column.



<12 Racing -- We don't know what it means either

I once was lost, but now I'm found.

GTSRolla34




Offline

1380 posts [100%]
San Antonio TX

  » Reply  Edit


I would also like to see that as I have been looking for an intermediate shaft option to lengthen my power column. I don't feel totally comfortable with the welded option.
Sbailey294




Offline

1735 posts [97%]
Philly PA

  » Reply  Edit


Andrew;
Any "subjective" feelings on the rack....tell us about what it feels like. I know thats hard but humor us if you can.



Steve

Esoteric Performance... don't compromise.

GTSRolla34




Offline

1380 posts [100%]
San Antonio TX

  » Reply  Edit


Also, if you know about the MKIII Intermediate shaft please share any information you may have or any source where the information may be found. Thanks.
Max_Misawa


Offline

30794 posts [99%]
San Jose CA

  » Reply  Edit


KP61 and TE72 racks can be used
Tercel u joints can be used
and Supra intermediate shafe can be used

Fujiwara86 (Rick) is running this setup

no cutting, no welding, no fabricating invloved
its all junk yard parts
and it all bolts up to the stock GTS steering columb

Max



Send me an e-mail

Maxfrommisawa@aol.com

No More Toll Free Number Sorry Guys :(

GTSRolla34




Offline

1380 posts [100%]
San Antonio TX

  » Reply  Edit


What year Tercel?
Max_Misawa


Offline

30794 posts [99%]
San Jose CA

 Re: (GTSRolla34) » Reply  Edit


i dunno
my buddy just did this swap so i know it works though

Max



Send me an e-mail

Maxfrommisawa@aol.com

No More Toll Free Number Sorry Guys :(

assassin10000
Teq



Offline

4959 posts [100%]
Northern CA

 Re: AE86 Quaife QSR & Manual steering info. (MidTenn Drifter) » Reply  Edit


Quote, originally posted by MidTenn Drifter »
Great write up once again. Added to the Tech reference. I'd be interested seeing back up information on the MKIII Supra intermediate shaft in the PS column.

Done. (info @ bottom of first post)

Andrew

BadSmog
Member



Offline

398 posts [94%]
sacramento CA

  » Reply  Edit


Hey Andrew, just a quick question, how did you take apart those U joints connecting to the intermidiate shaft to the column? Did you use a press? Or did you hammer them? I just need to swap my shaft so i can complete this conversion, if the U joints are too dificult to take apart i'll just weld it... thanks man.
orangekid




Offline

3249 posts [87%]
please, no pictures...

  » Reply  Edit


you don't take apart the u-joints...you just have to get the intermediate shaft out of the column...I used a vise and a hammer...
BadSmog
Member



Offline

398 posts [94%]
sacramento CA

 Re: (orangekid) » Reply  Edit


oh man, thanks a lot, i dont really know much about toyotas because i recently switched from a nissan and i was going to take it apart at the U joint haha. wow i feel dumb. Still learning here, it looks very obvious now....
BadSmog
Member



Offline

398 posts [94%]
sacramento CA

  » Reply  Edit


i was also going to make a U joint that fits on the manual rack since the power steering doesnt fit and i've been to junkyards looking at mr2's and ae86 and couldnt find one, so i was going to take 2 U joints of PS racks and take the small ends and piece them together....
orangekid




Offline

3249 posts [87%]
please, no pictures...

  » Reply  Edit


i tried to hammer apart a PS u-joint to do that...it wasn't happening...
BadSmog
Member



Offline

398 posts [94%]
sacramento CA

  » Reply  Edit


yeah i did the same and took one apart and all the little bearing inside shattered everywhere.....so yeah.
GTSRolla34




Offline

1380 posts [100%]
San Antonio TX

  » Reply  Edit


How did you remove the intermediate shaft?
assassin10000
Teq



Offline

4959 posts [100%]
Northern CA

 Re: (GTSRolla34) » Reply  Edit


PB blaster soaked & let sit overnight. I was able to grab it with a large pair of channel lock pliers (12-14" in size) and slide it out.

I did remove the whole steering column from the car when I did mine tho.

On the supra one I took the intermediate shaft with the lower u-joint that connects to the rack. PB Blaster'ed (sp?) again. Put the intermediate portion into a vice, and used a crescent wrench & a hammer to pound off the u-joint/lower portion.

Andrew

BadSmog
Member



Offline

398 posts [94%]
sacramento CA

  » Reply  Edit


I'm gonna try to soak mine in WD40 seems like its the same as PB blaster. I took my column off so i'm gonna let it soak overnight and see how it works. Thanks.
irishtwincam


Offline

560 posts [99%]

  » Reply  Edit


http://www.skynet.ie/~eireae86...D.jpg

I have a manual AE86 rack and knuckles.
In addition to teh quaife racks above you cans see the BV kit/kit2? I forget which it is.

How many teeth must I get cut into the quaife rackand where abouts on the rack?
Can someone take a picture of a modified QSR and normal QSR side by side?

Paintbrush the cuts even?

assassin10000
Teq



Offline

4959 posts [100%]
Northern CA

 Re: (irishtwincam) » Reply  Edit


Quote, originally posted by irishtwincam »

How many teeth must I get cut into the quaife rackand where abouts on the rack?

Can someone take a picture of a modified QSR and normal QSR side by side?

2 extra teeth to use the BV #2 kit in your picture.

I don't think there is ANYONE who has had both the modified & unmodified at the same time except for Long (xXRidgeRacerXx/Socal Spec). You'd have to see if he has the pictures still.

Andrew


insane




Offline

253 posts [100%]
Farmington NM

 Re: (assassin10000) » Reply  Edit


What kind of shop will do the machining of the teeth?
also What advantage do you get with the quafie and battle version kit #2?

I have a factory manual setup now.



Glass stays crunchy in milk!
assassin10000
Teq



Offline

4959 posts [100%]
Northern CA

 Re: (insane) » Reply  Edit


Quote, originally posted by insane »
What kind of shop will do the machining of the teeth?
also What advantage do you get with the quafie and battle version kit #2?

I have a factory manual setup now.

More angle... I haven't really gotten a chance to use the #2 kit yet. I'm going to play with different combos (ie manual knuckles/#2 kit, power knuckles #1 kit, etc) to see what fits best for me.

Andrew

insane




Offline

253 posts [100%]
Farmington NM

 Re: (assassin10000) » Reply  Edit


So a stock manual rack and one modded with a quafie have the same amount of angle?
I have a battle version #2 kit so if you could tell me how you modified your quafie to accept the #2 kit I would really appreciate it. here is a write up from Alex, this may save you some time as it explains the results of the different combos you plan on trying:

http://www.battleversion.com/a...s.htm



Glass stays crunchy in milk!
assassin10000
Teq



Offline

4959 posts [100%]
Northern CA

 Re: (insane) » Reply  Edit


Quote, originally posted by insane »
So a stock manual rack and one modded with a quafie have the same amount of angle?

Yes, same amount of angle. Stock for Stock, IE: no spacer kits/tie rod ends.

I didn't modify my QSR, the guy/shop I bought from sent it to a machinist and had extra teeth cut. As noted in the first post iirc.

Andrew

insane




Offline

253 posts [100%]
Farmington NM

 Re: (assassin10000) » Reply  Edit


Okay after reading about the group buy now I am confused. do you have to get the extra teeth cut in where the pinion gear contacts the rack or on the ends where the tie rods bolt in?



Glass stays crunchy in milk!
GTSRolla34




Offline

1380 posts [100%]
San Antonio TX

  » Reply  Edit


The group buy rack will have extra teeth precut. So you shouldn't need extra teeth. They will be sufficient to run with inner spacers (battle version) or longer inner tie rods that have a spacer machined into them.
insane




Offline

253 posts [100%]
Farmington NM

 Re: (GTSRolla34) » Reply  Edit


sounds good.



Glass stays crunchy in milk!
Akuma Dori Development
Member



Offline

1805 posts [100%]
3 Stars And A Sun

  » Reply  Edit


the gts manual rack and pinion housing is shorter in lenght compared to the aw11? is that true?



* Three Stars And A Sun * Drifting Division *

ilovemy86@yahoo.com


assassin10000
Teq



Offline

4959 posts [100%]
Northern CA

 Re: (Akuma Dori Development) » Reply  Edit


I don't know about the housing length, never compared them side by side. BUT I am aware of the fact that the pinion shaft that the u-joint connects to is taller/longer on the aw11 rack than the ae86.

Andrew

23psi4age


Offline

993 posts [89%]
Pembroke Pines Florida

 Re: AE86 Quaife QSR & Manual steering info. (assassin10000) » Reply  Edit


Question - i have a tiny bit of play in my steering - and when i shake the steering wheel from left to right in that play it makes a clunking noise on dead center. any idea if my QSR is not installed correctly or if other parts of my steering system maybe installed incorrectly?

something isnt right.



'85 Coupe Sr-5
Beams 3sge + 6speed + JDM = My Dream Car!
 First  1 2 3 4 5 >  Last



» Return to Cars - RWD - (AE86, TE, KP, RA, TA)
Forum Jump
Quick Reply

 


ZeroForum 3.0 beta-8. Execute Networks Inc.

 

NOTICE to ALL who are involved in transactions, sale, purchase for listings in Classified sections of Club4AG.

Club4AG will not and can not enter into dispute or act as mediator for any disputes taking place in our web forums, and sections are merely designed to provide a communication channel for buyers and sellers. And because we are not mediators or a sales channel for transactions, we will not rate, or grade any sellers or buyers as we are not equipped to tally concrete facts for any parties involved, in any transactions.
Any and all actual transactions should be taken with normal precautions of finding and collecting information and securing your sale/purchase to satisfactory levels. All further communications of dispute or resolving any matter of transactions should be conducted outside of the forums.   We suggest you make note of as much information about the sellers and buyers, such as telephone number, email, physical address, etc, before doing any transactions, and use a protected methods like Paypal or other merchant services to secure your sales or purchases. Unlike eBay or Amazon, Club4AG does NOT take middle ground, serve as mediators, or keep, make available, provide, or record any information of anyone on this web for use in dispute resolutions, and Club4AG will NOT rate, grade, or give/receive feedback of anyone conducting sale or purchases here.  This site is provided for announcements of sale and wanted ads only, just as any newspaper classified ads, or bulletin boards in community centers.