Need creative solution - loose debris in steering column 911SC
 

Last year while trying to install an "upper steering column bearing" bushing repair sleeve (928-347-739-02-M737 Bushing, 911/912E/930 1974-89) on my 1980 911SC, I was having difficulty getting it to seat, and in an act of colossal stupidly, I used the steering wheel and nut as a press and applied too much force, shattering the upper steering bearing, and sending debris including the inner race and all the ball bearings down into the steering column. I was able to cut the outer race out of the steering column with a dremel tool. I considered leaving the inner race and bearings in the column, but found that the balls were apparently wedging somewhere and not allowing the steering to turn freely and fully in both directions. After much difficulty, I retrieved the inner race and what I thought were all the balls and debris using a couple of long, thin screwdrivers whose tips I had magnetized. The steering moved freely, and it appeared that I had retrieved all the debris. I installed a new upper bearing and all was good. Or so I thought.

Subsequently, I have discovered that with exactly the right combination of bumps in the road and steering angle, when steering mildly left, the steering will suddenly and unexpectedly lock solid, although when this happens, turning back to the right even a bit completely frees up the steering. Obviously, I have a piece of debris floating around down there, and I am guessing that when the steering is positioned just so, that debris can become wedged between the steering column and perhaps the cutout in the steering shaft for the steering lock. Just as obviously, I cannot continue to drive the car until I resolve this issue.

Removing the steering column completely from the car is not an option, as it is a huge undertaking and beyond my ability. So the car has remained parked for months while I have tried to come up with a creative solution. I thought about placing a powerful magnet on the underside of the steering column in the area where the loose debris would be, hoping the powerful magnetism would hold the debris in place. However, I am concerned that over time the debris itself might become magnetized, since it would still be free to move slightly, and then someday when it bounced again, it might stick to the steering shaft. So I don't think this is such a good idea.

I thought about removing the steering lock assembly to use that existing opening in the steering column to try and reach the debris, but I have previously had it out when replacing an ignition switch, and from that experience I don't think I can get enough access to get a magnet into the area where the debris is located at the bottom of the column. (There is not very much clearance between the I.D. of the steering column and the steering shaft, and the debris would be approximately 90 degrees from the steering lock hole.)

The other idea, which I am about to pursue in the next day or so, is to use a Dremel cut-off disc to cut a slot in the bottom of the steering column, perhaps 5mm wide and 10-15mm long, into which I could insert something like a coat-hanger wire with a small magnet epoxied to its end, and retrieve the debris. I have attached a photo showing approximately where I propose to cut the slot. (Perhaps the debris would even be located in the area that the slot would be cut.)

So, that's my dilemma. I would be interested in input and suggestions regarding my proposed solution and any other suggestions anyone might have. I don't like the idea of cutting the steering column, but it is in an area that is not visible under normal circumstances, and I do not think a slot of that size would materially compromise the functional strength of the column.
Any and all opinions are welcome and appreciated! (Although if your opinion is that I am a complete idiot for causing this mess in the first place, thanks just the same, but I am quite aware of that already! ;) ) Thanks for your input!

http://forums.pelicanparts.com/uploa...1355089099.jpg

Sure could use some opinions on this...

I think I would get another steering column from someone here or at the recyclers.

I like the slot idea. All that runs in there is the steering shaft held by the bearings at either end, which is much smaller in diameter than the column itself.

Will it weaken the column?..Yes, but not significantly.

The worst thing that can happen is you will have to remove the steering column, which is your only other option anyway.

I say go for it, I love the creativity. I just got done tearing thru my steering system, rebuilt the rack, upper bearing too, but did not tackle the column, mine seems to turn great with no noise and very smooth, couldn't justify the headache to take it apart.

Enough time has elapsed that you could have removed the steering column, disassembled it, fixed your problem, re-installed everything, taken a trip to Paris, learned three languages and raised a family.

Sometimes, what seems hard isn't a big deal, in the end. Pull the column out and fix it right...

JR

STOP driving it until it's fixed. We want you to live. Pull the column, disassemble, remove debries, add new parts/lube, reassemble, reinstall, drive w/ a smile on your face.

I found a way to remove the top bearing without removing the column - search for:

Steering shaft removal w/o removing column!

(sorry I don't know how to post a link to a thread)

This will let you pull the top bearing and vacuum out your junk - it will also let you replace the bearings, eliminating the shim fix.

HTH,
Chuck.H
'89 TurboLookTarga, 343k miles

Chuck,

Nothing special about it. Copy the internet address of the post you want to link peeps to. You have to go into that post. Paste the address into the text when you write up a post. Leave some space before it and after it to not get it confused/connected with your own typed words.

Simple copy/paste.

Although the slot idea sounds good, without knowing how the column and steering rack are built internally, I think there is a serious danger by not replacing the assembly. If a ball bearing was to jam into the rack and pinion you could wreck. Or, ball bearings in the steering shaft could jam or bind your ability to turn. Not good. You will never know if you got all the loose parts out until its too late.
If you can replace the steering bearing, you can do this job, no problem.

Or better yet, click the little globe/chain icon in the "reply to thread" dialog and paste the link there. That way its a clickable hyperlink.

Here is ChuckH's shaft removal procedure using the globe chain icon

http://forums.pelicanparts.com/porsche-911-technical-forum/704056-steering-shaft-removal-w-o-removing-column.html

"Plans go wrong for lack of advice; many advisers bring success." Proverbs 15:22

Thank you, each and every one, for your replies. I SO appreciate your advice!

The thing that had stopped me from pulling the column in the first place when I originally caused the problem is the 3 tamper-proof bolts holding it in place. It looked to me like I would have to take the dash completely out of the car to access them! I really appreciate the links to other threads that had lots of helpful info, including easy ways to get those bolts out. I no longer feel that this is beyond my abilities to do. (but it does make me TIRED just thinking about it! ;) )

@Chuck and @Bob, thanks for the links to "Steering shaft removal w/o removing column". I think this is the approach I will take. If only I had read this one back when I was replacing the bearing, I would have pulled the shaft then and gotten ALL the debris out! Oh well, live and learn. At least with this method it doesn't look like a lot of extra work to get the top bearing out of the way, and I'm right back to where I started.

I still think the "access slot" idea is a creative shortcut that would work. But I really don't want to modify my car in any way, even if it wouldn't show. And I just feel better about getting the shaft out and being able to KNOW there's nothing left down there.

All-in-all, I wish I'd seen a lot of the stuff you Commenters led me to back when I first had my problem! I wouldn't be re-doing it today if I had.

Thanks again, everyone! :)

Ok, I've started attempting to remove the ventilation box (air handler) from the car, so that I can access the steering column. However, after getting the fan out of the way, it is looking to me like I'm going to have to drill some rivets out in order to remove the box.
I have searched Pelican's forums, as well as the internet, and don't find any step-by-step instructions on removing the air handler.
I would sure appreciate it if someone could direct me to an appropriate post, or could post instructions here.
Thanks!

Here's what I posted in your other thread about this question:

What part do you mean by air handler?

If you identify which part you are talking about, I'll tell you how to remove it.

JR

JR, thanks for taking the time to reply. I was out all evening, and by the time I got back Nick had answered my question in another thread. I appreciate you taking the time to respond!
- Paul

Hello PJ1,

The same thing happend to me, (broken bearing while taking apart)
Balls from bearing assembly fell into the column shaft, replaced with new bearing...
Go for a drive... steering lock for a moment during a turn.
Removed debries( 3 balls ) from steering lock mechanism hole with a magnet on a small stick.

Thanks Pierre, I'll give that a try.
- Paul