Steering Rack Brace

[chrisp]

Abbott Racing used to make a brace for the Saab 9-3/Cavalier steering rack that replaced the nearside rack rubber bush and clamp with a solid aluminium one and then had a triangular brace across to the nearside suspension tower bodywork. This was said to stop the steering rack flexing the bulkhead, provide much more positive steering and also eliminate the risk of bulkhead cracking that has afflicted some Cavaliers and Saabs. When I contacted them recently they said that now they only make a brace for post-1996 Saabs and Cavaliers and they have discontinued the pre-1996 one. Can anyone confirm that the Cavalier steering racks changed design in 1996 and, also, does anyone know where I can get a pre-1996 rack brace for my 1993 Cavalier V6?

[Robsey]

In 1996 the Cavalier had already been replaced by the Vectra-B.

Although there is an American car called a Cavalier that was made up to at least 2008.

So in simple terms, there should be nothing available for a 1996 Vauxhall Cavalier / Vectra-A.

[Robsey]

I did find this though.

How to make your own?

http://photo.platonoff.com/Auto/2005040 ... and_Brace/

[chrisp]

Thanks for this reply and, yes, Abbott Racing now only advertise for sale rack braces for Saab 9-3, 9-5, 900, 9000, New 9-3 and New 900. I think these are all post-1996 but, unlike the Vectra B that replaced the Cavalier around 1996, the Saabs retained their Cavalier-like steering rack and bulkhead mounting of it.
Abbott Racing did at one time make a rack brace for the pre-1996 Mk 3 Cavalier, but they have discontinued it, presumably because of lack of demand. What I was really asking is: does anyone know of any old stock of these pre-1996 braces and also, does anyone have any knowledge of whether the post-1996 Saab braces can be adapted to fit a 1993 Cavalier?

[iangsi]

There was an episode of Wheeler Dealers they did a Saab & used a brace, but I can't remember what make brace they used. I remember thinking I might fit one to my GSI at the time but never got around to doing anything about it. Not much help but another line of investigation.

[chrisp]

Yes, it was that episode of Wheeler Dealers, which I viewed last week and that showed a brace being fitted to a Saab 9-3, that got me investigating where I could get a brace from for my 1993 Cavalier V6. The under-bonnet layout of the 9-3 looked identical to my Cavalier, but Abbott Racing say that the only brace that they currently can supply is not suitable for pre-1996 Saabs or Cavaliers. I think the diameter of the steering rack may have changed from 1996 onwards. Braces for pre-1996 Cavaliers and Saabs certainly were made and I was hoping that someone may have some old stock that I could buy. So far, though, I've drawn a blank.

[Robsey]

I have looked all over for a rack brace, butit is like they never existed.

Tried all the usual performance specialists, to no avail.

As you suggested, a used unit may be the only option... but equally as hard to find anything except 10 year old Saab or MigWeb forum posts.

Could you not get something made up?

It doesn't look too complicated.

Aluminium two-piece clamps (one for each end).
Then link / bracing bars to each suspension tower.

Although it looks like the kits only braced one end.
The ABS module / Battery side.
----------------------------------
There are various ways to do it...

Anti-roll / torsion bar from one clamp to the other.
Thick alloy load-spreading plates on the cabin side of the fire-wall / bulk head.

And so on...

[3cav3]

At the back of my mind Car Mechanics magazine did something along these lines back some where between 2000 and 2010 to a 93 Saab seem to remember the company was called 2 stroke to turbo? Might be worth a Google search?

[Robsey]

Do you mean here?

https://twostroketoturboparts.co.uk

[chrisp]

Thank you for these replies. I checked the Two-Stroke to Turbo website and a search there did not bring up any steering rack braces. Still, I've submitted a query to them and will post back here when I get a reply.
As for making up a brace myself, the crucial aspect is the fit of the aluminium bracket that bolts to the bulkhead on the nearside and clamps the steering rack. This is itself braced to the nearside suspension tower via the ABS unit bracket. The aluminium bracket replaces the standard rubber bush and pressed steel clamp, and is what stops movement of the rack under steering load which eventually cracks the bulkhead on the offside. So the bracket needs to be a tight fit onto the steering rack. Apparently the rack diameter changed from 1996 onwards on Saabs (the Mk 3 Cavalier gave way to the Vectra at that point, I think). so the currently available steering rack brace from Abbott Racing will, they say, only fit 1996 onwards Saabs. Therefore, making up an aluminium bracket that will fit my 1993 Cavalier is, I think, going to be impossible without casting and machining facilities.
I've also sent a query to PFS (Parts for Saabs, www.partsforsaabs.com) who advertise a post-1997 brace, to see if they still can supply a pre-1996 one. I'll post any useful reply here.

[chrisp]

Parts for Saabs (www.partsforsaabs.com) has now replied to my email about whether the brace they sell for the Saab 9-3 (their ref. PFS902894) would fit my 1993 Cavalier. Unfortunately they say they have no experience of Vauxhalls and have never tried such a fitment - and they recommend I take the matter up via a Vauxhall forum! Ho-hum - another dead end. It's not vital that I fit such a brace but I am using the Cavalier more at the moment - and enjoying the V6's power and smoothness - but am noticing some flex in the steering. Once you've noticed this you can't un-notice it!
I'm still waiting for a reply from Two Stroke to Turbo, the other Saab specialist that I contacted.

[James McGrath]

Steering racks are a bit of a weakness on the bigger engined Cavaliers.
Especially if they are driven briskly all their lives.

I have steering rack problems on my V6 and Diplomat that will need sorting soon.
Generally cracking of the bulkhead was more of a problem with Astras of the time rather than Cavaliers.
Mainly it's just the rack itself that wears out and causes major issues with the tracking.
Grab one of the steering arms in the engine bay and try to move it up and down. If there is any movement then it's likely the rack is worn.
Luckily it's all fixable.

The Cavalier chassis, although fairly good for the time, is a bit floppy.
This becomes more apparent as you go up the range and the weight increases.
My 1060KG 1.6 LS feels sweet as a button when driven hard around corners and is very confidence inspiring.
My 1315KG 2.5 CDX, although can go round corners faster, doesn't feel anywhere near as precise or consistent while cornering.

Anyway, I'm very interested in the results of this. I'd be tempted to get one too if it works.
Good luck in your search.

[chrisp]

I've now found what I think to be the issue with post 1996 steering rack braces - which are still available from Parts for Saabs and Abbott Racing. In or around 1996, the steering rack diameter, where it is clamped to the bulkhead on the nearside, became much smaller. Saab kept the same metal clamp but increased the thickness of the rubber bushing between the clamp and the rack to take up the extra space. This made the rack even more subject to movement than on pre-1996 cars. This is illustrated in the 2nd picture down in the right hand side on this website:
http://photo.platonoff.com/Auto/2005040 ... and_Brace/
The Parts for Saabs brace clearly has a diameter to suit the newer smaller steering rack diameter, as can be seen on this webpage:
https://www.partsforsaabs.com/product_i ... 1017e2c78b
So it definitely will not fit the earlier cars with a larger diameter rack.
Unless there is an increased demand for the earlier, larger diameter, brace and a manufacturer (like Abbott Racing or Parts for Saabs) can be persuaded to re-make it, I don't see any hope of getting this brace for any Mk3 Cavaliers.
A small improvement could probably be made by replacing the standard rubber bushing on the Cavalier (nearside at least, maybe also the offside one if it can be accessed) with polyurethane ones. Does anyone know if such bushes are available?

[chrisp]

I think I've answered my own question in that I've found a Polish supplier of polyurethane steering rack mounting bushes. These are listed for the Calibra but I'm sure will fit the Mk 3 Cavalier. There's a choice of standard or slightly harder 'Sport' bushes. The supplier is FMIC Performance (https://fmic.eu) and the part numbers are 131417A (left) and 131416A (right), though I think this numbering is for European LH drive cars so will be reversed for UK RH drive ones. The A suffix is for the yellow Sport bushes, the same numbers with a B suffix are the red standard bushes. Prices are reasonable - around 12 Euros each plus tax, so I've ordered one of each of the Sport bushes and will see how I get on. Fitting the nearside (left) bush will be relatively easy - access is good. The offside (right) bush will be more difficult - it is right under the brake servo and the large engine on my V6 Cavalier is very close to that, so access is very constrained.

[chrisp]

I have received the 2 (LH and RH) polyurethane steering rack bushes for my V6 Cavalier from the Polish company FMIC.eu. However, BEWARE if you're thinking of ordering these. The "RH" bush (LH or nearside in the UK) inexplicably has the same part number for two different internal diameters (131416A, 36mm and 51mm). The 51mm version fits the Cavalier, the 36mm version is for the Opel Kadett (and I suspect the Saab 9-3). Of course, I ended up ordering the wrong one - the order details in the basket do not indicate which size you've ordered, so you have to be very careful to click on the correct one when ordering and also add a comment to the order about the diameter required. I've now re-ordered this item! On the plus side, these bushes are good and hard and I think will hold the steering rack almost as firmly as the aluminium clamp that is no longer available for the Cavalier.

[James McGrath]

Good info there. Thanks for updating.
I'm planning of getting my V6's rack refurbished at some point and I think I'll get some of these fitted at the same time.

[Mazza]

Very interested topic.

I actually have a brace from Abbots for my turbo project. Although it’s a long way off before it’s actually fitted.

I’d be keen to hear how you get on and the end result.

[chrisp]

I'm still waiting for the correct 51mm ID polyurethane (ref 131416A) nearside bush to be delivered by FMIC.eu - they seem to be in short supply compared with the 38mm version. In the meantime, i've taken a risk and purchased the brace kit from partsforsaabs.com (their reference PFS902894, £93.90). As expected, the aluminium clamp for the rack is the wrong size (it looks to be the 38mm diameter), but the brace itself is the correct size and shape to fit between the existing rack clamp, and a bolt of the subframe that is currently in use solely to support the ABS unit bracket. I reckon that, with the harder polyurethane bush and the brace installed, the extra rigidity will be almost as good as with the aluminium clamp. I won't know for sure of course until I've actually fitted this stuff - and I'm not going to start that job until I actually have the correct polyurethane bush. I'll post again when it's done.

[chrisp]

Well, the correct 51mm ID nearside polyurethane steering rack bush arrived, so I set about trying to fit it. However, I found that the steering rack needs to be removed - or substantially moved away from the bulkhead - to be able to remove the metal U-shape bracket that holds the bush. It is constrained by one of the power steering feed pipes. I tried to move this (accepting there would be a spillage of power steering fluid) but it is held to the rack with a brass nut with a small hexagon socket. I could not move this with an Allen key and when I applied more force with a hexagon key, the socket in the brass nut just rounded off. So, for now at least, the existing rubber bush (which looks to be in reasonable condition) will have to stay. The good news is that I found the brace itself can still be fitted - using the special nut supplied to secure it to the lower stud that holds the rack U-shape bracket, and securing it to the lower subframe via the fixing for the ABS-unit support bracket. The latter needs the existing bolt to be removed (this is another hex socket set screw, but came out easily enough with an Allen key), and replaced with the longer bolt supplied in the brace kit. It's a bit of a fiddle getting this longer bolt in and tightened because of severe lack of space, but a curved obstruction ring spanner did the trick. I should mention that I may be more space constrained than other Cavaliers because of the V6 engine and auto transmission which are quite bulky. Anyway, the brace does appear to improve the steering feel - particularly in the straight-ahead position where the car feels less 'wandery' and needs less continuous correction. So I think it is a worthwhile addition, but my advice would be: if you ever have the steering rack removed, take the chance to replace BOTH rubber bushes with polyurethane ones.

[Robsey]

Thanks for sharing this with us.

I don't suppose you managed to get any pictures, to show how the parts looked before and after fitting.?

Being limited to 113 bhp (C20NE), I have never thought to worry myself about flexing of the bulk-head or tearing around the mounting points.

In my own ignorance / naivity, I always put any vagueness, under-steer or wandering down to worn track rod ends, wishbone bushes or low tyre pressures.

[chrisp]

I'm having trouble trying to upload the image. Clicking the "Inset Image" button just puts (img)(/img) into the text. I also can't drag and drop the image file - which is jpg format - into the text. Can someone please advise how to do this, and I'll post the image of the installed brace with some comments. Thanks.

[Robsey]

This is Chrisp's intended post and pic.

This picture is the after-installation one only, as I did not take a "before" one.



The picture is taken from the front of the car looking back and down towards the bulkhead on the nearside, behind the ABS unit.

Three "pipes" are visible - the top two are the power steering feed & return pipes, the bottom one is not of course a pipe but the track rod. (The rough appearance of these is just Waxoyl underseal that I took the opportunity of applying).

It's the second power steering pipe that prevents the removal of the U-shape bracket that holds the rubber bush and steering rack.
The top mounting for this U-shape bracket is a bolt, but the bottom one is a long stud and this gets in the way of manipulating the bracket so it can be removed.

You'd need to move the steering rack around 2 inches away from the bulkhead to be able to free the bracket and remove the rubber bush, and to do this you'd need to also release the bracket on the offside of the steering rack - which is buried beneath the brake servo.

The brace itself is the chrome plated cranked item item which is attached to the bottom U-shaped bracket stud via a sort of tube - which provides clearance for the brace around the steering rack.

The other end of the brace is secured to the bolt hole that is used to mount the ABS unit bracket - using a supplied longer than standard bolt. I am of course aware that, without the (no longer available) aluminium clamp that replaces the rubber bush and U-shape clamp for the steering rack, the brace will only stop flexing of the bulkhead and will not stop any possible movement of the rack within its rubber bushes.

Replacing the rubber bushes with polyurethane ones would certainly firm up the rack mounting and, if I ever need to remove the steering rack, I'll certainly fit these.

[3cav3]

Being limited to 113 bhp (C20NE), I have never thought to worry myself about flexing of the bulk-head or tearing around the mounting points.

113? My Astra is about 56bhp, hopefully means I should in that case never have an issue lol. Especially if I stick to the skinny original tyres?

[James McGrath]

I've just ordered myself a set of polyurethane bushes for my V6. Going to get them fitted along with a new rack at the end of the month.

What brace did you fit in the end?
Was it this one?

https://www.partsforsaabs.com/product_i ... 1017e2c78b