Rebuild Koyo Power Steering Rack (AWS)
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- čas přidán 30. 12. 2023
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I cover the Caswell Black Oxide kit in much greater detail 28 minutes into "Galant VR-4 April Progress" • Galant VR 4 April Prog...
For people with a Galant VR-4, if you can't find a service to rebuild the rack you have, your options are extremely limited except to rebuild it through your own sheer grit and determination and you will have to accept the challenge of chasing down the parts you need for it however you can get them. That's what happened here. The Galant VR-4 has a Koyo rack.
I had the foresight to buy multiple seal kits over the years in an attempt to obtain either the proper Galant VR-4 kit OR some of the rear seals to rebuild this car's rear steering rack with very little success. Both of the aftermarket kits I purchased were listed for the Galant VR-4, but without factory replacement part kit availability, you can only take what you can get. I was gifted with cores to pull parts from for the major components I couldn't re-use. For the non-reusable, if it didn't come in that parts kit, I can't order it from Mitsubishi, so I'm out of luck.
I had to rob bits from other kits and even supply some of my own O-rings to make them complete. I show both kits, but neither kit is complete for this particular rack. One was actually for the non-turbo Galant rack with was different as demonstrated. Fortunately it was similar enough that most of its seals and o-rings worked.
The Mitsubishi Seal Kit part number for this 4WS rack is MB815189
The rack itself is MB532130 and good luck with that.
This car is not coming back with All Wheel Steering. It's coming back instead with the rear axle assembly it truly deserves. What little is still in tact from its rusty dysfunctional AWS hardware will be parts for another all wheel steering system on a different car if it needs it. While all wheel steering is an important part of a Galant VR-4's personality, and an interesting piece of technology, it is not the critical or centerpiece of the Galant VR-4's performance. It works precisely as advertised but its affects are minimal, and it's largely was a sales ploy as well as an answer to Honda's AWS Prelude in the US market. So while this is the correct power steering rack & pinion assembly for a Galant VR-4, the car with 4 wheel steering, it's only going to do two wheels now and the rebuild is 0% different either way. It's well explained in the video.
This would be the same procedure for ALL first generation DSMs, and anything Mitsubishi with a Koyo rack no matter how many wheels it controls. The hydraulic 4WS system used here is the same as the 3000GT VR-4. Koyo makes a high quality power steering rack and they ended up in lots of other great cars, Toyotas, GTR's... but changes that should be very minor may result in major differences even across the same make/model/year as you will see.
The special seal shrinker tool I used is called a MB991317, if you find one, you're lucky. No you can't borrow it.
There are only 6 bolts, 5 nuts, 2 tie rod ends, a seal kit, and 3 washers in 37-050. Beyond that, pretty much every part is named something like cushion, band, clip, pad, bracket, and trying to buy any of that from Mitsubishi is fruitless for this car. You may get lucky with the nuts and bolts, and you may find some things on Rockauto, but if it's not in current production and you can't find it in the aftermarket, and you don't have a core to rob from, then you are going to have to be creative.
The only bolts and nuts I didn't cover in the video are
4 qty. MF241307 Bolt, Steering Gear Washer Assembled M12 x 25 x 1.25mm Grade 7 60-80 Nm or 43-58 Ft-lbs
They hold the rack into the subframe. I put anti-seize on those bolts.
The steering shaft support lock nut ring thing gets 51 foot pounds, but you'll never get a wrench that big that lets you measure that.
The socket/special pinion tool thing has never surfaced in my antique tool searches for 17 years. And now I'm done with this job, replaced it with a rag and a socket, so I think I'll pass on the expense of its novelty if I ever find it. It's gotta hold 1 foot pound. I hope I saved everyone $100 in tools and hours of worry.
This was actually an easier job than making the video about it. It took me about 20 hours of video because of all the cleaning, blasting and painting. No matter how you slice it, if you can find the right rebuilt rack for $300, do that instead. Don't blink. It's true that fixing your own car is putting money back in your own pocket, but on this job you make more per hour doing something else. You gotta either really love the thing or want the challenge. I can say I enjoyed this experience. Just look at it. Major #1229 problem solved. Now we can move on... - Auta a dopravní prostředky
Pause at 0:38 with high resolution settings to see the entire 37-050 parts list.
I was hoping you were gonnasay boobies.
My favorite part is near the end of the description when Jafro says "I enjoyed this experience".
Thanks man! I had multiple outs over the years and some attempts were actually taken before deciding that this one is one I had to face down. I really was trying to save the AWS but the car said no. It's not the right car for it. The block already said no to the stock internals. The internals want more than a 16g. So I feel like I did the right thing for this one, I beat the unsavory job, and I think this will help other people figure it out.
Jafro, I am a car guy, have been since I could barely walk. That being said, I have never owned a DSM, I don't plan on owning a DSM, and in most cases I don't care for the DSM'S ( Minus that 2 door EVO V) Personally I prefer the Nissan S chassis. That being said, I started watching your videos maybe 12 years ago. I have watched every video since. You're an absolute godsend of a help to the DSM community and I truly wish you had this level of love for the S chassis community. Thank you for your hard work and endless knowledge, though I may never use it I am sure you have saved people endless hours of fruitless research. I cannot wait to see what you do with these cars!
I dont see a DSM in my future again but your attention to detail and general desire to recycle instead of replace keeps me coming back!
Love that Gojira hoodie, oh and cool to see the innards of a power steering rack, never really understood how they worked until now.
...and brother, this is what I love about my audience. I actually didn't explain anything about how it works beyond what you needed to fix it, and I know my audience can look at all the dirty bits inside and figure all of it out! We save each other so much time like this!
I know your pain and patience when it comes to the spreadsheet. I'm currently doing the same thing for my SAAB 900. I'm about 92% complete - 2000 parts cataloged and 3000 pics so far. I also zinc plate my own hardware for the entire car, so my bench grinder is like my side chick - my wife is jealous with all the time it gets
Good on you for rebuilding the stock rack. I tried a reman rack for my '91 talon restoration and it failed in a few thousand miles. I took it apart to put a seal kit in myself, and the thing was full of blasting sand! Absolutely destroyed. Luckily I installed an inline filter in my return line so the pump survived.
I do not understand how you do not have more subscribers....your content is great...keep it up man, love the progress, always a treat to see a new video.
Best. CZcamsr. Ever. Still. And. For. All time. ❤
I say this in the best way possible, but you make restoring a car look so hard! Still, I learn much more from your meticulous style than from the usual quick and dirty, slap it together work you usually see on CZcams. You raise the bar. Thanks for making me think "What would Jafro do?" anytime I mess with anything on a car. Happy New Year, my fellow Virginian!
Wow...
Watching you do all if this detail oriented work reminds me of myself when I was 17or 18...I had an'89ProbeGT- a twin of the Mazda MX6GT and they both had the tough little 2.2 SOHC12 VALVE TURBO ENGINE :" F2T" I took everything off of the engine that was ugly gray,cast aluminum(valve cover, exhaust manifold heatshield, the aluminum turbo "volute" and I sat in my driveway for a couple weeks with a "D.A."handsander and I attacked all the aluminum parts first with 80grit sandpaper, then worked all the way up to 2k grit... when I was finally finished I could see my reflection in anything that was made out of aluminum it was all a mirror shine- and so,Anytime I went to the local "car hangout" and Popped my hood, everyone would come gather'round to check it out ...it was very cool😅 ...hell of a lot of work but, in the end it was worth it
Taking pride in your work is ALWAYS worth it!!!
i love you man. you are the best on youtube. seeing all the parts laid out looking better than they did in the factory for a car nobody but us and 50 other guys remember is such an awesome feeling
Just wait until you see how bad it makes the rest of the car look when I put it all back together!
shout out to Jaffro Patreon supporters!
Oooooh, that turned out looking sweet!
Nice work, friend! I admire your dedication.
Also: Thanks patreons
Although I throughly enjoyed your content Jafro, it hurts my heart to not see the GSX getting love.
It can't get the love it needs until the green one can roll, and the green one just had the most significant mechanical problem it came with fixed. So working on making the green one roll right on out of here is actually helping the GSX! It's also clearing off multiple shelves the GSX needs for me to keep going with it because these subframe parts are huge.
Thank you so much for making this. Knowing how to rebuild a steering rack is useful for, as you said, when you can't just get the part anymore. I'm glad I'm not the only one that entertained rebuilding mine
Watched every minute of it without a skip, love everybit of Jafro when i can get it. Some very useful info and unique tools used for this job!
First new Jafro vid I've seen in a while, good to see ya.
Omg! This gives me flashbacks to rebuilding my donor steering rack for my 1992 SVX. Mine has variable steering assist too, and it was nearly identical to this with the exception being mine didn't come equipped with AWS, like every other USDM model. Mine original unit was too pitted to rebuild, so I rebuilt a donor. It wasn't fun.
1:15 You are not alone my friend. I'm in Poland and lately I'm strugling to even find someone with two brain cells to swap tires on my cars.
happy new year jafro and all fellow jafro enjoyers!
That was amazing. Such a great video. Cheers!
Always learn some valuable dsm knowledge watching your videos jafro.
Super excited to see the end product
I've been waiting since the 2017 cliff notes to see this video come out. Love the progress update. Thanks for sliding one out just before 2024.
Great work and incredible attention to detail as always. I'm right alongside you with my own weird old JDM car restoration project. Slowly plugging away at it.
I ended up just pulling a manual rack out of a 1.8 dsm to put in my Galant.
Thanks, Jafro, It's been a long journey over many years, enjoyed every one of them!
Boy are you right! The channel about what it's like to CZcams your DSM hobby when you have a day job to pay your bills and a property to maintain. How it does move at the speed of life. lol. Yes. Long journey! Sorry for that, but I we might as well always have a good time at it.
I’ve waited so long for steering rack content and I’m so glad I chose to put a manual rack in #231. I picked up a 1g power rack also before I chose Manual. You saved me trouble there. Maybe I will make this journey in the future should I decide to reinstall 4WS.
I’m pretty sure I read/found out the 4bolt lsd will bolt into the GVR4 pumpkin to keep rear steering in tact but upgrade to LSD and stronger axles. This has me wanting to hoard my galant rack.
See ya next year 👍
Good job, bring it back to life
Brilliant as always jafro
For years the best of the best ! Thanks Jafro !!!
Great video as always Jafro! 👍
5:52 Jafro trying to sneak in some Tyler Durden edits lol
Took me a hot minute to get to watch this one, awesome vid as always, i would have loved to see a clear coat after the cover come off the factory label. and that is the biggest ratcheting ring spanner I've ever seen.
I know! I had to buy it just to finish this job. There was a bigger one at least twice its size. I almost bought it for comic relief, but then I realized I'd need a wider toolbox for it and it would be like a $3,000 joke. So I had to pass.
turned out awesome !
It is a pleasure watching you work 👍😎
Thank you! Cheers!
as always, great video, great work...
All the best and all the best in the new year! Also, its nice of you to give us a video like this for i don`t even know which time it is by now on the new year... As a solo machinist, i spend new years solo, so this always hits the nail!
I'm in a happy place when I have a table full of clean, restored and inventoried parts with brand new bearings and bushings. That is my satisfaction. And I finally put a whole thing together instead of just taking things apart and cleaning them for once! These are the moments we all work our butts off to achieve. Putting stuff back together, and here I have a table with the past year's work, all tidied up... and this is what we have to look forward to. I'm grateful for you, and for all of this. 2023 was not easy for me, but this is something to feel really good about. All of this happened because of you. So I'm thankful to all of you. This is precisely what I knew we all needed to see. Happy New Year!
@@Jafromobile
Love hearing you are in a good state! I`ve been watching your stuff for years now, what on this channel and what on my old one, and it`s always a pleasure seeing your work... You are a gift from the Providence to this world, entertaining, teaching, maintaining cool shit and passing on the skills or the theory of the works on to anyone who has similar interests and lingers on... I picked up a lot of things from you over the years, and you encouraged me in some ways to be more relaxed when facing work on complex assemblies... Hell, i have 12 large machines in my shop, all bought with restoration in mind, and i can`t wait to reach the moment where you are currently - putting the machines back in order, fully restored to their quondam grandeur, rather than being in a state of disarray as they currently are...
All the best and kindest regards! Also, all the best in the forthcoming year!
Steuss
Yay, I got notified. Great video, Jafro, happy New Year to you and your family!
great vid and perfect timing, i'm about to rebuild my subi rack.
Love your work jaffro wow you’re doing things I’ve always wanted to do
I'll be honest, I could feel your pain when you were comparing the parts on the steering rack.
Happy New Year!
happyp new year Jafro!
amazing work!
You are not alone in the pain of finding rebuild parts for a power steering rack... I finally rebuilt my power steering rack about 9 months ago for a 2005 Hyundai Elantra and found out pretty quick that the genuine hyundai seal kit was missing the one seal I actually needed... The rack bush seal is not included and not even referenced as a seperate part. I instead (after buy another two random seal kits...) that you just have to buy the entire rack bush assembly which is an expensive affair.
Another interesting thing is how similar your koyo power steering rack is to Mando Hyundai rack. The hyundai rack doesn't have the bolt on the bottom of the pinion gear though. I tried a seal kit I found randomly on aliexpress for a toyota rack but the steering gear shaft in smaller by 1mm in the hyundai so the seal for the toyota and I assume your mitsubishi is 1mm bigger in both inner and outter diameter.
So in the end I used 3 rebuild kits to make 1 power steering rack...
Happy New Year Jafro
Yay a video
Happy new year Jafro 😊😊
I always get the right parts.... 👀
Great job. This video inspired me to get the reman unit when the time comes. 🤣🤣🤣
I would not bother with the straps. Just get the tool for tying wire and do a double wire hose lock on it. That thing's rather for pressure (not hydraulic pressure, but still pressure) it's more than good for a boot and it's very clean. Bonus point: it doesn't cut up the boot because wire's round.
To expand teflon seals use a crock pot with oil in it, or in your case ATF.
Watching you blast things and seeing the dust around u I’d say ware a mask u don’t want silacoses
Oh my god that parts list. You make me almost wish ibwas a DSM guy with the quality of these tech vids.
Even to me it feels like an anthology of cheat codes for all of my favorite games.
Love your videos jaffro! Please keep em comin!!
-long time mitsu fan from NY
If you hear the zip-whiz sound a captive washer makes against a wire wheel every damn time you close your eyes, it's probably time for a day off.
Awesome job but unfortunately I think you'll find those bolts will rust pretty quickly. It's usually coupled with an oil coating; that black oxide helps accept... but even still, it's very poor at preventing corrosion.
👍
🎉🎉
Man. I want to visit your shop sometime... Btw I'm also in the rva area! Justin at detective tells me you always have a project going on
You went to Virginia Tech, didn't you?
Ive got maybe a dozen 4g63 heads and parts from my days as a machinist/dsm enthusiast. As far as i know dsm graveyard isnt a thing anymkre. Any idea where i could unload them without getting taken to the cleaners?
Oooft channel locks right on ground shaft.
On the washer actually... but I did make believe there for a second to scare everyone first.
@@Jafromobile dam I've been rocking backwards and forwards for the last 4 hours out of fear.
If the company pays no tax or very little, at the end of the year, Uncle Sam doesn’t get much, it goes to the place you bought that part from. Maybe some sales go local.
What ever happened to the red of the chocolate? Miss the old days!
The only sad thing about mitsubishi is really hard to get parts now for the old hero cars. Tried to help my friend with a evo 6 to get rear cv shafts. Couldnt get anything new.
I thought Raxles makes new CV axles.
Yeah, nah. Not for the past decade. Sorry, I've talked to them about it back then, they couldn't source the joints anymore. Our community has always destroyed axles, and they're every bit as sad about it as we are. Next step is DSS.
You can get Evo 7/8/9 RS rear complete driveshafts new and they fit Evo 4/5/6 RS
Jafro, does Rojo Del Chocolate has their music for sale anywhere on the internet?
Those band clamp pliers are utter garbage...until you put a small chamfer on the inside of the jaws, they then work like a charm and don't squash the clamp ears flat
is this the same parts for a 3000GT VR4?
Mostly. Keep in mind the kits I bought that were the right part numbers for a Galant VR-4 did not contain the complete set of parts that I needed. I had to buy 2 different kits to get the full set I needed. When I did that it was an accident because I forgot I bought the first one. Neither kit was fully correct, and that accident saved me when I was shooting the video. The seal kits are dirt cheap, so buy several that are spec'd for your car anyway. I think you can get them for between $20-$30 each. I've seen as low as $11, but that was 5 years ago when everything in the world wasn't broken.
While searching the part number for my steering rack, I found websites that listed my searches as 3000GT parts. They showed exploded diagrams, drawings, that were exactly what my parts are, and I was searching part numbers from my Galant. I did not compare every part, but they listed the full parts list similar to what I drew for the Galant with all of the part numbers. I didn't have to join anything or pay anyone for access to that info, so search these part numbers and I bet you'll find it!
...additionally, when you get into them, usually the needle bearings and roller bearings are fine. But if you need to replace them, and your rack is a Koyo, the part numbers are etched on the outside of the races of each bearing.
@@Jafromobile found them on Amazon for 65 dollars. If you know a place to get them for those prices let
Me know
@@joseantoniodaly4875 Search for the kits by THEIR part numbers, not the Mitsubishi ones. I also collected these parts over a span of 10 years. The $11 kit was definitely observed over 5 years ago. I didn't even buy it. I've noticed that Amazon raises the prices of everything I every try to buy if I passed it up the first time or if I've ever bought it before.
when a gsx video
Speaking of wrong parts, one time I ordered an Alternator and got an AC fresh in the sealed box.
Happy New Year Jafro