Steering shaft mod

[Matt_aka_Dale]

Hey all. While I'm doing repairs to the steering, I was wondering if there is a steering shaft mod for a '89 3.8L SC with long tube headers? I did a quick internet search and I found a link to a mid length header mod on TCCoA. It looks perfect, but it will definitely not work with my setup. I had asked a similar question about it on SCCoA about 5 years ago and I was recommended to use a thicker header gasket on that side. Has anyone else run into this?

 

[Zep5.0]

Hey all. While I'm doing repairs to the steering, I was wondering if there is a steering shaft mod for a '89 3.8L SC with long tube headers? I did a quick internet search and I found a link to a mid length header mod on TCCoA. It looks perfect, but it will definitely not work with my setup. I had asked a similar question about it on SCCoA about 5 years ago and I was recommended to use a thicker header gasket on that side. Has anyone else run into this?

I thought all of the headers available worked with the stock shaft on SCs?

 

[Matt_aka_Dale]

I went ahead and put the thicker gasket on but I'll have to wait on an update until it's completely back together. However I will say that it does indeed push the header out a bit more. The new gasket is roughly 3-4 times thicker than a typical gasket.
I also decided to check the telescoping steering shaft. I was getting a slight knock sound out of it when I would hold and rotate it and when jouncing up and down. I might as well replace that too I suppose.

 

[XR7-4.6]

In my mind when I think “steering shaft mod” what comes to mind is relocating where it comes out of the firewall outward utilizing an intermediate U joint, which people using unmodified mustang headers/manifolds can do(I had one for years until I got my Kooks and went back to the stock shaft).

If you have headers made for SCs though you shouldn’t need anything that dramatic, if there’s fitment issues you can use thicker gaskets as you did(I love my remflex gaskets btw!), or slightly dent a primary where it interferes. Another solution which @97 30th did was use a longer section of the thinner inner DD shaft off the rack joint and shorten the DD sleeve that normally goes all the way to the rack, giving about 1/8” extra clearance

 

[Matt_aka_Dale]

These are kooks with a dent.
With that remflex gasket on there now, it should have more clearance as is.

"Another solution which @97 30th did was use a longer section of the thinner inner DD shaft off the rack joint and shorten the DD sleeve that normally goes all the way to the rack, giving about 1/8” extra clearance" I'm interested in this, but I would need instructions/parts list.

I'd honestly consider another stock shaft, but would not want to have another worn one.

 

[Matt_aka_Dale]

I've been hard at work with this! I have done a bit more research and taken my chances with trying aftermarket modifications.
Aside from the modifications already mentioned, I have found that this solves the telescoping steering shaft problem: Borgeson
- #45025 24" telescopic shaft
- #014952 u-joint (3/4DD x 1DD 3-1/4 length)

The #45025 shaft will need to be trimmed. I fully extended it and measured from the end of inner shaft up to the outer sleeve. Cut the outer sleeve roughly 21 3/4". Then from the cut end, measure 1/2" in and drill through one of the flat sides of the sleeve (the side opposite of the already dimpled side of the inner shaft). This drilled end will go into the #014952 u-joint.

Now the fun part. Push the inner shaft mostly back into the outer sleeve and run it through the shaft boot on the firewall(If you trim the black plastic sleeve from the old shaft, it can be slid on the new shaft). Take the #014952 u-joint and replace the stock joint on the steering wheel by putting the 3/4DD end on there. The new shaft will be slid into the 1DD end(make sure drilled hole on the sleeve matches the long set screw on the #014952). Tighten the set screws and we are done with the upper part.

On the lower part, or inner shaft side, I had to file down and smooth roughly 1"~1 1/2" at the dimpled end the shaft so that it would fit in my Flamming River u-joint**. Match up the shaft dimple with the set screw and tighten down.
**If a Borgeson splined u-joint is used in place of a FR joint, the shaft may not need to be filed and smoothed.

Now that this has been done, the steering shaft has about 1/4"~3/4" of space away from the headers. No more hitting the header and no more slack in the steering.