I finally got to looking at the steering this afternoon. This is what the left end of my rack housing looks like:
This is where the play in my steering is coming from (per earlier in the thread, I could feel it with my hand here) and also the occasional clunk over left-wheel bumps. This is where the bushing and retainers shown here (nos. 17-19) are supposed to be:
I haven’t pulled the boot all the way back but I don’t feel anything floating around in there. I haven’t pulled the boot off the other side for visual comparison since I don’t want to make extra work for myself.
This is what I think should be visible:
https://forums.pelicanparts.com/porsche-911-technical-forum/1155791-steering-rack-side-bushing-help.html#post12186787
Per this:
https://forums.pelicanparts.com/porsche-911-technical-forum/1117749-steering-rack-silentblock.html
Someone did at one time machine some replacements:
https://forums.pelicanparts.com/porsche-911-technical-forum/1123706-these-steering-rack-parts-available.html
Apparently this McMaster-Carr part is suitable for the star nut:
https://www.mcmaster.com/90635A415/
And this is either part $18 or a bunch of these can be stacked for the bushing? I’m not clear:
https://www.mcmaster.com/4061T241/
Someone else apparently machined themselves a pair of bushings:
https://forums.pelicanparts.com/porsche-911-technical-forum/1140702-steering-rack-et-al-yet-again.html
So, I have questions. I do not have access to machining equipment or a machinist, unfortunately. Possibly a friend of mine could do it on his lathe.
Can one of you confirm that this is Not Right?
Does anyone have specs for the bushing for machining one?
Any other potential sources for a replacement? I saw a post where someone mentioned that a team called Red Dog Racing has made some, but that doesn’t seem like a viable option at the moment.
Can I remove the inner tie rod with the rack in the car, or is it going to have to come out?
The car has been like this for quite some time, but it’s not something I’d like to leave as it is any longer than I have to now that I know what the problem is.