STEERING COLUMN REMOVAL/REFIT 1989 928S4 WITH PIC'S.
NOT FOR THE FAINT-OF-HEART OR ZERO 928 EXPERIENCE! GOOD TO HAVE A FRIEND TO HELP IF POSSIBLE. THIS TASK IS A MINIMUM OF 6-10HRS DEPENDING ON YOUR EXPERIENCE WITH 928s AND ACCESS. A LIFT IS BEST AS YOU NEED TO RAISE/LOWER THE CAR A LOT. STEERING COLUM ASSEMBLY PIC FROM A 928 GTS.
1) Drive car to your lift or where you want it on your drive for axle stands.
2) Disconnect battery and raise car to remove undertrays.
3) Remove complete dash pod. There are many write-ups on this so just view Theo's website for instructions or see here:https://www.yumpu.com/en/document/view/43161123/porsche-928-s4-dash-removal-landsharkoz Also remove ignition wiring cover with unscrewing small hexhead screw on left and disconnect wiring. Leave key in ignition in on position to stop steering lock engaging.
5) Remove steering column spring on the left of column. Long nose pliers required.
6) Go under the car and undo the top steering union locking nut attached to the splined shaft from the steering column.
7) Go back up into the car and holding the 2 metal arms off the steering column, pull towards you whilst twisting side-to-side to pull the steering column out the bulkhead and separate the steering union and splined shaft. The steering column assembly should eventually pull away. There is a rubber seal in the bulkhead the column passes threw; if this is too stick to get the column out use some lubricant.
8) Congratulations! You have the steering column removed! Have a break.
9) Do whatever work you wanted to get the steering column out for.
1) Go under the car and mark lower steering union as (L) and where it's positioned on the splined shaft off the steering rack. Remove steering union from the steering rack by undoing locking nut/bolt and hammer off.
2) Where the steering unions have a long split in them, drive a flatblade screw drive into them (without breaking them!) to open them up for reinstalling. Lubricate unions and splined shafts off steering rack and column with some super slippy lubricant. Also lubricate the inside of the seal that the steering column passes thru at the bulkhead and the column itself where the rubber seal sits. Reinstall seal to bulkhead.
3) Put steering column back into the car thru the dash and just far enough into seal in the bulkhead to start the large black column piece.
4) Go back under the car. Hold the splined shaft hanging down from the steering column and push on the upper steering union as far as possible.
5) Go back into the car and hand tighten in loosely the 3 hexhead screws and fixing plates that hold the steering column on. Use a small round screw driver to align the plates/screw holes. Don't fully tighten the screws yet as you need some wriggle room.
6) Go under the car and hammer the top steering union upwards until you can align the lower steering union with the splined shaft off the steering rack.
7) Centre and lock rack to align steering.
8) Align and Hammer on lower steering union. Use a long pry bar to align lower steering union whilst hammering on.
9) Install locking nuts on upper+lower steering unions+tighten.
10) Go into car and fully tighten 3 hexhead screws.
11) Reinstall steering column spring with strong long-nose pliers with column at uppermost setting. Use some strong tape on column to hold spring fixing firmly.
12) Replace ignition wiring and ignition wiring cover with small hexhead screw on left.
13) Reinstall dash pod, undertrays and connect battery.
14) Test steering on lift and check everything still works on dash (fingers crossed!).
15) Go drive your 928 on a road trip as a reward for this hard work/and/or go on a holiday for a rest!
SOME TIPS. You cannot install the steering column with the steering unions attached with the engine in sit. There isn't enough room behind the engine. It took me well over an hour to admit defeat on this one!
2)Make sure you open up the steering unions as far as possible without breaking them and use generous amounts of lub, otherwise you will really struggle to get them back on as hammer room is very limited.
3) Make sure your steering union locking nuts are super tight.
best to all 928 owners.