Yes, Jim, that would be great. I would really appreciate that. I'll source some new bolts in the meantime.

Why is this job so difficult if the parts come in a kit? I should be getting mine today from PP and I am not sure I want to bother now. Should I go ahead and source longer bolts before starting? Send the kit back and use the wheel alignement shims?

The kit has nothing to do with why it's difficult. The kit is simple and straightforward. The problem is threading the damn bolts. If you removed the old ones, moved the rack a round and tried to reinstall the old bolts, you'd still have a hard time. I have a hard time threading the bolts on the belly pan every time I do it too.

Come on RL, confess. How many brewski's did you slug down before you started working on this? I mean, with federal jury duty facing you, you must've been up for a whole lotta PBR's. :D

My lubricant was Moskovskaya vodka from the duty free shop in Berlin-Tegel Airport and cranberry juice. And yes, I'd had a lot of it by the time I gave up.

I hear cranberry juice is good for you. :)

We get it fixed in a couple of days and you'll be back in action. Did you replace your steering rack boots yet? Any problem with disconnecting the tie rod ends from the struts?

I haven't even started thinking about that job since I began the rack spacer install.

LOL! :D

Don't be scared off. I installed the spacers, it wasn't that bad except for the underbody crud and dirt falling on my face (wear goggles). I put antiseize on the bolts and started them by hand or at least holding the wrench with only fingertips. I don't recall any "crap x-threaded" moments but I do recall it took several tries to get the rack and bolts lined up so that the threads would catch. Took about 2-3 hours.

I'm left handed...it only took me 20 minutes. :D

I'm both handed.... it'll take me 10 minutes. :D

This is an easier task with the tie rods disconnected.

My recommendations:

1 - Remove one bolt (they can be very tight)
2 - Insert longer bolt into hole and thread into bar 3-4 threads
3 - Loosen rack u-joint
4 - Remove other bolt
5 - Lift up rack, install spacer over hole where you just removed the previous bolt
6 - Install longer bolt & tighten slightly
7 - Remove bolt on opposite side and install spacer
8 - Tighten bolts and u-joint

By only removing one bolt at a time, you maintain the location / registration of the rack.

-Wayne

Thanks Wayne, but it's too late for that. Both bolts are out.

If you remove the washers can you get one bolt started? Then follow Wayne's suggestion.

I dont know exaclty how many hours it took me to put in the two spacers and reinstall the two xmember bolts, but it was alot. I would pry on the xmember with anything that would fit, it would look like the holes were lined up, but I still couldnt get the bolts in. My process was to lay underneath the car for an hour and try unsuccessfully to thread the bolts, get really pissed off, reread the 101 Projects book to see if missed something, nope didnt miss anything, notice the 101 Projects difficulty rating level of "a dimwitted moron could do this job", throw a tantrum while spinning around in circles with my ratchet in hand. I am not sure what i did different, if anything, to get the bolts in, but I did end up getting them. Good luck, I am sure that you will be successful soon.

I am just back from a test drive with the rack spacers installed.
WOW!!!! What a freakin' difference!!!
The car feels so much better. No kickback whatsoever. I found the bumpiest roads I usually travel for the test and it was fantastic.

The install took me about an hour. I went by the instructions in 101 Projects and mixed in a little of this thread. I used my floor jack to push the rack gently up just enough to install the shims. I did one side at a time. I guess I was lucky. No binding in the linkage, either.

Just got four new bolts in case I tear up two more. Not sure if I'm in the mood to try again tonight, when Jim is coming over Fri. with a tap and die kit. I fear I may have boogered up the rack threads. 993 has big issues too, so I'm about Porsche'd out for a few days.

RL, spend some quality time with your truck while the gas prices shoot back up. That'll get you in the mood for wrenching Fri. night. :)

DONE!!!!

Thank you, Jim RIchards. I owe you a non-alcholic Pabst.

How f$#ked would you feel when you see you have totally shreded the threads in your rack? Well, Jim retapped them after we dropped the rack (removed t-bars, cross member, tie rod ends, etc.). One side went right in. Other side took a while, since I hadn't correctly loosened the coupler in the smuggler's box. Didn't realize that bolt had a nut on the other end and it had just been spinning before. Other bolt took a while, but we made it. We counted threads on the ride height bolts, so it's probably pretty close. But my rack boots were shredded too and guess what - yes, I was sent the WRONG new ones. So I'm off to the stealer tomorrow to try to find the right ones, button her up and then drop her off for a front alignment. Then it's time for RA-1's and I have a DE in mid-Oct.

THEN I get o deal with 993 BENT rear suspension parts. Can't wait! It NEVER ends. Just killed that bottle of Moskovskaya.

Can't leave you in a spot where track time is at risk. :)