I'm finally getting around to fixing the front end of my car after a tire wall incident last year. Need some help re-installing the steering rack. Never done this before. It is a manual NA rack on a 1990 1.6.
I replaced the front subframe and removed my steering rack to check for straightness. I wasn't able to get the u-joint to slide off the intermediate shaft so I first tried to pry it open with screw drivers and such and eventually resorted to hitting the u-joint with a hammer. Seems like rust is fusing the u-joint to the shaft and rack (it was an east coast car). The hammer worked but instead of the u-joint sliding out of the intermediate shaft, the intermediate shaft slid out of the column at the area near the fire wall. Unfortunately, the hammering bent the tab on the u-joint that the pinch bolt threads into and here is where I am today....
1. Is there a way to remove the u-joint from the shaft going into the rack? My u-jointed is foobar'ed from the hammering so I need to replace it...
2. I noticed the intermediate shaft has a couple of flat spots but the area where it inserts into the column near the firewall does not have any sort of index that I could find. Does the intermediate shaft need to slide into the column in any sort of orientation based on the flat spots?
3. Is the intermediate shaft from a power steering car the same as a manual steering car? I think I have a spare.
Any advice or answers to questions that I don't have the experience to ask?