new steering rack doesnt reach steering column shaft?

[XBW]

anybody have a clue why my new junkyard steering rack wont reach the steering shaft?

the rack is in and bolted up but there is a small gap between the steering box shaft and the steering column shaft, meaning its still about an inch too short?
im 99% sure its the correct rack, but havent measured the distance from the clamping bracket to the top of the box shaft, but i did measure the little shaft itself, it is the same.

2 things i need to mention
1. the nuts up in the crossmember brackets had to be replaced, so instead of welding in new nuts i welded in new bolts, the welds might have gotten in the way but i ground them down and also drilled out the lower bracket holes a little larger so that they would fit around in case. But even then the rack should go all the way up against the upper bracket.
2. the passenger side bushing was junk so i replaced it with a 240sx one i had laying around, it is a bit thicker versus the stock one. But i doubt this would affect the drivers side.

heres a borrowed pic to show where my problem is, cant get these two close together

https://sl-i.net/FORUM/images/imported/2011/02/P1012451-1.jpg

[chuckthefuk]

The thickness in bushing will drasticly change the mounting distance compared to using stock/poly specific bushings..

Are you sure you have the correct rack?

Did you have to change any of the p/s lines?

Did you happen to compare old vs new before you put it in.

Where did you get your rack from?

Here is a 98 LGT rack and a 97 L rack.. Pretty much identical...
https://sl-i.net/FORUM/

-Chuck

[XBW]

yeah i briefly laid the new one next to the old, and my eye didnt catch any differences.
i did not change any lines, they look identical.

i got the rack from a local yard, off of a 98 or 99 outback iirc. i have a 97 outback
somewhere i read that 99 and up racks use 30mm bushings while older use 25mm ?

i thought this was interesting, some guy lifting a regular legacy after installing OB spacers:

After spacing the front crossmember the larger gap between the column and the rack will be too big for your old knuckle. I found it easiest to remove the two bolts under the ignition key and have a friend hold the wheel while I lined up the splines then just push it back in and bolt it back up.
https://sl-i.net/FORUM/images/imported/2011/02/24004842173_large-1.jpg

[chuckthefuk]

Regardless... You put a Outback rack on a Outback.. you should not have any issues with the "intermediate u-joint"

Replace the bushings with an OEM unit and fix those welded nuts .... It just sounds like your cross-member is sitting to low..

-Chuck

[bobbyjimmy]

If it's a 99 rack, it will be the next model (Gen III, BH) and they have spacers on the crossmembers which are 1" thick which means they also use a 1" longer steering linkage/knuckle/uni.

[mike-tracy]

If it's a 99 rack, it will be the next model (Gen III, BH) and they have spacers on the crossmembers which are 1" thick which means they also use a 1" longer steering linkage/knuckle/uni.

That's what I was thinking, except in the States we got the 2nd gen's from 95-99. Perhaps the junkyard went by the manufacture date of the vehicle, so you really got one from a 3rd gen? I'm with Chuck - the 99 BK should be the same as a 97 BK

[Huffer]

If it's a 99 rack, it will be the next model (Gen III, BH) and they have spacers on the crossmembers which are 1" thick which means they also use a 1" longer steering linkage/knuckle/uni.

JDM/Australia/NZ = 99 = BE/BH
USDM = 99 = BD/BK/BG
USDM = 00 = BE/BH

[chuckthefuk]

This is ture ^^

However the 99 BK/BG used different transmissions then the 95-98's The 99 shares the Axle Stub style transmission thats in the 98+ RS.

I really don't know if this is set in stone but I got my info from http://spda-online.ca/modules/tinyconte ... tc_28.html (http://spda-online.ca/modules/tinycontent/rewrite/tc_28.html)

So that being said it looks like there is slight revisions to the USDM 99's before the Gen 3 stepped in.,

-Chuck

[Huffer]

I've found all kinds of weird anomalies in the USDM 99-00 Legacies... my theory is that Subaru started throwing various "end of model" parts into the 99 production line to make up for various part shortfalls. I've seen 99s with MAF sensors, MAP sensors, different length knock sensor cabling, 00+ 4EATs w/ spin on filters...

Anyway...

[XBW]

right...
well i just wiggled it some more and it went on :smt017

also i turned the steering wheel alot while disconnected... but no airbag light yet

heres why i replaced it :
http://www.youtube.com/watch?v=lv25HlbPzdc

[chuckthefuk]

:smt012
Well then.... glad everything worked out for you.

-Chuck