update, now its been in a week....
when i put it together, i set the preload clamp bolt ( the one that presses the rack onto the input shaft) as per the honda service manual instructions, tighten to 4nM, release, do it again, back off 20 degrees and tighten the lock nut.
the weight on the input shaft was then checked as per manual at 3Kg at 100mm lever length (ie. gently clamp on some grips on to the input shaft, measure out 100mm from shaft and pull at that point with a spring balance...) so i double checked it was about that, it was, and fitted it all in....
if this is how it's supposed to be, then no wonder auto cars get a bad press with 'dull' steering.... it's like driving in treacle.... yes it all does what it's supposed to but its heavy going.... i expected it to be tighter, as there's more drag on the shiny new motor bearings, but the motor assist will offset that...so a bit more investigation....
the eps rack, according to the service manual is set to a load of 3kg on the 100mm lever....
the manual rack is set, according to the book, at 1.5kg... so it's half the turning force when there's nothing connected to start with!
i then checked the rack i removed, which was comparable to the original rack when i swapped it in..... 0.7kg!!! no wonder Sarah thought it was really light when she drove it!
fortunately the rack clamp bolt is easily accessible under the car, so a quick jack up, back off the lock nut, do the double torque up, and back it off about 40 degrees, check there's no play or issues, there's not, so all back together... i did a spring balance check on the steering wheel before and after, and i suspect i'm closer to 2kg/100mm now, not as loose as the manual rack, so splitting the difference!
the result, much nicer
so, lost the knock going over bumps, the other rack had a small dead point when you rocked the steering (probably a combination of the torque sense mechanism getting sticky and play in the ball screw mount as well and hence this whole investigation) so obviously lost that, and lost a 'knock' from the input shaft every 360 degrees (probably that loose plastic gear related)
so that's the steering rack sorted!
...and i've got the one i took out to go through too..... at my leisure!!
aka Jonathan!!
'92 charlotte green auto.... as a daily
'37 Ford Y street rod......... something for the weekend!
...... if a photobucket pic is foggy, click it, and it'll take you to the clear version, yes, it's a clicking faff....