STEP 1: Immobolise Vehicle by disconnecting the battery.

STEP 1: Immobolise Vehicle by disconnecting the battery.

STEP 1: Immobolise Vehicle by disconnecting the battery.

STEP 1: Immobolise Vehicle by disconnecting the battery.

STEP 1: Immobolise Vehicle by disconnecting the battery.

STEP 1: Immobolise Vehicle by disconnecting the battery.

STEP 2: Jack up vehicle on a flat workshop area.

STEP 2: Jack up vehicle on a flat workshop area.

STEP 2: Jack up vehicle on a flat workshop area.

STEP 2: Jack up vehicle on a flat workshop area.

STEP 2: Jack up vehicle on a flat workshop area.

STEP 2: Jack up vehicle on a flat workshop area.

STEP 3: Remove steering column as per factory repair manual.

STEP 3: Remove steering column as per factory repair manual.

STEP 3: Remove steering column as per factory repair manual.

STEP 3: Remove steering column as per factory repair manual.

STEP 3: Remove steering column as per factory repair manual.

STEP 3: Remove steering column as per factory repair manual.

STEP 4: Remove steering box, ilder arm and drag link as factory repair manual.

STEP 4: Remove steering box, ilder arm and drag link as factory repair manual.

STEP 4: Remove steering box, ilder arm and drag link as factory repair manual.

STEP 4: Remove steering box, ilder arm and drag link as factory repair manual.

STEP 4: Remove steering box, ilder arm and drag link as factory repair manual.

STEP 4: Remove steering box, ilder arm and drag link as factory repair manual.

STEP 5: Make sure all OEM steering box, Idler arm bolt holes and chassis rails are in good order and free from burs, obstructions or damage.

STEP 5: Make sure all OEM steering box, Idler arm bolt holes and chassis rails are in good order and free from burs, obstructions or damage.

STEP 5: Make sure all OEM steering box, Idler arm bolt holes and chassis rails are in good order and free from burs, obstructions or damage.

STEP 5: Make sure all OEM steering box, Idler arm bolt holes and chassis rails are in good order and free from burs, obstructions or damage.

STEP 5: Make sure all OEM steering box, Idler arm bolt holes and chassis rails are in good order and free from burs, obstructions or damage.

STEP 5: Make sure all OEM steering box, Idler arm bolt holes and chassis rails are in good order and free from burs, obstructions or damage.

Important Note Australian Falcon models XB, XC, and XD chassis gusset will require a small amount of trimming to provide adequate clearance for the RRS rack brackets.

Important Note Australian Falcon models XB, XC, and XD chassis gusset will require a small amount of trimming to provide adequate clearance for the RRS rack brackets.

Important Note Australian Falcon models XB, XC, and XD chassis gusset will require a small amount of trimming to provide adequate clearance for the RRS rack brackets.

Important Note Australian Falcon models XB, XC, and XD chassis gusset will require a small amount of trimming to provide adequate clearance for the RRS rack brackets.

Important Note Australian Falcon models XB, XC, and XD chassis gusset will require a small amount of trimming to provide adequate clearance for the RRS rack brackets.

Important Note Australian Falcon models XB, XC, and XD chassis gusset will require a small amount of trimming to provide adequate clearance for the RRS rack brackets.

STEP 6: Install RRS conversion brackets onto the chassis rails and torque bolts to specified settings.

STEP 6: Install RRS conversion brackets onto the chassis rails and torque bolts to specified settings.

STEP 6: Install RRS conversion brackets onto the chassis rails and torque bolts to specified settings.

STEP 6: Install RRS conversion brackets onto the chassis rails and torque bolts to specified settings.

STEP 6: Install RRS conversion brackets onto the chassis rails and torque bolts to specified settings.

STEP 6: Install RRS conversion brackets onto the chassis rails and torque bolts to specified settings.

   The Steering box nuts and bolts torque settings are 40ftlbs     55nm.

   The Steering box nuts and bolts torque settings are 40ftlbs     55nm.

   The Steering box nuts and bolts torque settings are 40ftlbs     55nm.

   The Steering box nuts and bolts torque settings are 40ftlbs     55nm.

   The Steering box nuts and bolts torque settings are 40ftlbs     55nm.

   The Steering box nuts and bolts torque settings are 40ftlbs     55nm.

   The Idler nuts and bolts torque settings are 30ftlbs      38nm.

   The Idler nuts and bolts torque settings are 30ftlbs      38nm.

   The Idler nuts and bolts torque settings are 30ftlbs      38nm.

   The Idler nuts and bolts torque settings are 30ftlbs      38nm.

   The Idler nuts and bolts torque settings are 30ftlbs      38nm.

   The Idler nuts and bolts torque settings are 30ftlbs      38nm.

STEP 7: Using the bracket as a template drill chassis rail edge with a 8mm drill

STEP 7: Using the bracket as a template drill chassis rail edge with a 8mm drill

STEP 7: Using the bracket as a template drill chassis rail edge with a 8mm drill

STEP 7: Using the bracket as a template drill chassis rail edge with a 8mm drill

STEP 7: Using the bracket as a template drill chassis rail edge with a 8mm drill

STEP 7: Using the bracket as a template drill chassis rail edge with a 8mm drill

STEP 8: Fit load spreader plate

STEP 8: Fit load spreader plate

STEP 8: Fit load spreader plate

STEP 8: Fit load spreader plate

STEP 8: Fit load spreader plate

STEP 8: Fit load spreader plate

   The load spreader nuts and bolts torque settings are 18-20ftlbs      22-24nm.

   The load spreader nuts and bolts torque settings are 18-20ftlbs      22-24nm.

   The load spreader nuts and bolts torque settings are 18-20ftlbs      22-24nm.

   The load spreader nuts and bolts torque settings are 18-20ftlbs      22-24nm.

   The load spreader nuts and bolts torque settings are 18-20ftlbs      22-24nm.

   The load spreader nuts and bolts torque settings are 18-20ftlbs      22-24nm.

STEP 9: Fit rubber insulators to rack

STEP 9: Fit rubber insulators to rack

STEP 9: Fit rubber insulators to rack

STEP 9: Fit rubber insulators to rack

STEP 9: Fit rubber insulators to rack

STEP 9: Fit rubber insulators to rack

STEP 10: Fit U clamps around rack rubber and fit to up to rack checking alignment is correct to rack. If rack does not line up stop and call RRS.

STEP 10: Fit U clamps around rack rubber and fit to up to rack checking alignment is correct to rack. If rack does not line up stop and call RRS.

STEP 10: Fit U clamps around rack rubber and fit to up to rack checking alignment is correct to rack. If rack does not line up stop and call RRS.

STEP 10: Fit U clamps around rack rubber and fit to up to rack checking alignment is correct to rack. If rack does not line up stop and call RRS.

STEP 10: Fit U clamps around rack rubber and fit to up to rack checking alignment is correct to rack. If rack does not line up stop and call RRS.

STEP 10: Fit U clamps around rack rubber and fit to up to rack checking alignment is correct to rack. If rack does not line up stop and call RRS.

STEP 11: Install rack tighten until rack is firm against mounting bracket

STEP 11: Install rack tighten until rack is firm against mounting bracket

STEP 11: Install rack tighten until rack is firm against mounting bracket

STEP 11: Install rack tighten until rack is firm against mounting bracket

STEP 11: Install rack tighten until rack is firm against mounting bracket

STEP 11: Install rack tighten until rack is firm against mounting bracket

STEP 12: Connect tie rod ends making sure adequate thread engagement into sleeve

STEP 12: Connect tie rod ends making sure adequate thread engagement into sleeve

STEP 12: Connect tie rod ends making sure adequate thread engagement into sleeve

STEP 12: Connect tie rod ends making sure adequate thread engagement into sleeve

STEP 12: Connect tie rod ends making sure adequate thread engagement into sleeve

STEP 12: Connect tie rod ends making sure adequate thread engagement into sleeve

STEP 13: Tie rod end adjusters must be adjusted to allow equal range of movement (rack is centred).

Note: The RRS rack and pinion has built in steering stops and therefore OEM stops can be deleted

STEP 13: Tie rod end adjusters must be adjusted to allow equal range of movement (rack is centred).

Note: The RRS rack and pinion has built in steering stops and therefore OEM stops can be deleted

STEP 13: Tie rod end adjusters must be adjusted to allow equal range of movement (rack is centred).

Note: The RRS rack and pinion has built in steering stops and therefore OEM stops can be deleted

STEP 13: Tie rod end adjusters must be adjusted to allow equal range of movement (rack is centred).

Note: The RRS rack and pinion has built in steering stops and therefore OEM stops can be deleted

STEP 13: Tie rod end adjusters must be adjusted to allow equal range of movement (rack is centred).

Note: The RRS rack and pinion has built in steering stops and therefore OEM stops can be deleted

STEP 13: Tie rod end adjusters must be adjusted to allow equal range of movement (rack is centred).

Note: The RRS rack and pinion has built in steering stops and therefore OEM stops can be deleted

STEP 14: Modify steering column according to the type of column your car has fitted.

STEP 14: Modify steering column according to the type of column your car has fitted.

STEP 14: Modify steering column according to the type of column your car has fitted.

STEP 14: Modify steering column according to the type of column your car has fitted.

STEP 14: Modify steering column according to the type of column your car has fitted.

STEP 14: Modify steering column according to the type of column your car has fitted.

Non-collapsible columns

 

Non-collapsible columns have a press fit bearing below the indicator mechanism,

this will require replacement by the RRS top shaft and bearing

Non-collapsible columns

 

Non-collapsible columns have a press fit bearing below the indicator mechanism,

this will require replacement by the RRS top shaft and bearing

Non-collapsible columns

 

Non-collapsible columns have a press fit bearing below the indicator mechanism,

this will require replacement by the RRS top shaft and bearing

Non-collapsible columns

 

Non-collapsible columns have a press fit bearing below the indicator mechanism,

this will require replacement by the RRS top shaft and bearing

Non-collapsible columns

 

Non-collapsible columns have a press fit bearing below the indicator mechanism,

this will require replacement by the RRS top shaft and bearing

Non-collapsible columns

 

Non-collapsible columns have a press fit bearing below the indicator mechanism,

this will require replacement by the RRS top shaft and bearing

Once column is removed, cleaned and dismantled remove top bearing and casing.

Once column is removed, cleaned and dismantled remove top bearing and casing.

Once column is removed, cleaned and dismantled remove top bearing and casing.

Once column is removed, cleaned and dismantled remove top bearing and casing.

Once column is removed, cleaned and dismantled remove top bearing and casing.

Once column is removed, cleaned and dismantled remove top bearing and casing.

RRS upper internal column shaft and locater bearing and collar.

RRS upper internal column shaft and locater bearing and collar.

RRS upper internal column shaft and locater bearing and collar.

RRS upper internal column shaft and locater bearing and collar.

RRS upper internal column shaft and locater bearing and collar.

RRS upper internal column shaft and locater bearing and collar.

NOTE: on some vehicles steering wheel to blinker housing interference may occur, this can be remedied by either cutting back the die cast blinker shroud or cutting new cir-clip grooves in the steering shaft further down.

NOTE: on some vehicles steering wheel to blinker housing interference may occur, this can be remedied by either cutting back the die cast blinker shroud or cutting new cir-clip grooves in the steering shaft further down.

NOTE: on some vehicles steering wheel to blinker housing interference may occur, this can be remedied by either cutting back the die cast blinker shroud or cutting new cir-clip grooves in the steering shaft further down.

NOTE: on some vehicles steering wheel to blinker housing interference may occur, this can be remedied by either cutting back the die cast blinker shroud or cutting new cir-clip grooves in the steering shaft further down.

NOTE: on some vehicles steering wheel to blinker housing interference may occur, this can be remedied by either cutting back the die cast blinker shroud or cutting new cir-clip grooves in the steering shaft further down.

NOTE: on some vehicles steering wheel to blinker housing interference may occur, this can be remedied by either cutting back the die cast blinker shroud or cutting new cir-clip grooves in the steering shaft further down.

Check the base of the column and mark it to be flush with the fire wall.

Check the base of the column and mark it to be flush with the fire wall.

Check the base of the column and mark it to be flush with the fire wall.

Check the base of the column and mark it to be flush with the fire wall.

Check the base of the column and mark it to be flush with the fire wall.

Check the base of the column and mark it to be flush with the fire wall.

Cut column to length, de-burr and clean cut, remove scam ridge if necessary.

Cut column to length, de-burr and clean cut, remove scam ridge if necessary.

Cut column to length, de-burr and clean cut, remove scam ridge if necessary.

Cut column to length, de-burr and clean cut, remove scam ridge if necessary.

Cut column to length, de-burr and clean cut, remove scam ridge if necessary.

Cut column to length, de-burr and clean cut, remove scam ridge if necessary.

Lower column bearing mount

Lower column bearing mount

Lower column bearing mount

Lower column bearing mount

Lower column bearing mount

Lower column bearing mount

Slide RRS lower column internal shaft into bearing housing.

Slide RRS lower column internal shaft into bearing housing.

Slide RRS lower column internal shaft into bearing housing.

Slide RRS lower column internal shaft into bearing housing.

Slide RRS lower column internal shaft into bearing housing.

Slide RRS lower column internal shaft into bearing housing.

Once the column is completely assembled and installed, a lower column support plate, which is provided by RRS, if applicable to your vehicle.  You may need to drill your column support plate and mount it to floor.   This required to be fitted in such a way as to provide a secure anchor point that will correctly align the steering uni’(so as not to cause any universal joint bind)

Once the column is completely assembled and installed, a lower column support plate, which is provided by RRS, if applicable to your vehicle.  You may need to drill your column support plate and mount it to floor.   This required to be fitted in such a way as to provide a secure anchor point that will correctly align the steering uni’(so as not to cause any universal joint bind)

Once the column is completely assembled and installed, a lower column support plate, which is provided by RRS, if applicable to your vehicle.  You may need to drill your column support plate and mount it to floor.   This required to be fitted in such a way as to provide a secure anchor point that will correctly align the steering uni’(so as not to cause any universal joint bind)

Once the column is completely assembled and installed, a lower column support plate, which is provided by RRS, if applicable to your vehicle.  You may need to drill your column support plate and mount it to floor.   This required to be fitted in such a way as to provide a secure anchor point that will correctly align the steering uni’(so as not to cause any universal joint bind)

Once the column is completely assembled and installed, a lower column support plate, which is provided by RRS, if applicable to your vehicle.  You may need to drill your column support plate and mount it to floor.   This required to be fitted in such a way as to provide a secure anchor point that will correctly align the steering uni’(so as not to cause any universal joint bind)

Once the column is completely assembled and installed, a lower column support plate, which is provided by RRS, if applicable to your vehicle.  You may need to drill your column support plate and mount it to floor.   This required to be fitted in such a way as to provide a secure anchor point that will correctly align the steering uni’(so as not to cause any universal joint bind)

The column is now ready to fit back into the vehicle.

The column is now ready to fit back into the vehicle.

The column is now ready to fit back into the vehicle.

The column is now ready to fit back into the vehicle.

The column is now ready to fit back into the vehicle.

The column is now ready to fit back into the vehicle.

Double Tube collapsible columns

 

Double tube collapsible columns are most easily identified by a corrugated lower outer column case.

Double Tube collapsible columns

 

Double tube collapsible columns are most easily identified by a corrugated lower outer column case.

Double Tube collapsible columns

 

Double tube collapsible columns are most easily identified by a corrugated lower outer column case.

Double Tube collapsible columns

 

Double tube collapsible columns are most easily identified by a corrugated lower outer column case.

Double Tube collapsible columns

 

Double tube collapsible columns are most easily identified by a corrugated lower outer column case.

Double Tube collapsible columns

 

Double tube collapsible columns are most easily identified by a corrugated lower outer column case.

Internally is another telescopic tube through which the steering shaft passes.

Internally is another telescopic tube through which the steering shaft passes.

Internally is another telescopic tube through which the steering shaft passes.

Internally is another telescopic tube through which the steering shaft passes.

Internally is another telescopic tube through which the steering shaft passes.

Internally is another telescopic tube through which the steering shaft passes.

It is necessary to completely dismantle this type of column so that the inner tube can be shortened 3.5".

It is necessary to completely dismantle this type of column so that the inner tube can be shortened 3.5".

It is necessary to completely dismantle this type of column so that the inner tube can be shortened 3.5".

It is necessary to completely dismantle this type of column so that the inner tube can be shortened 3.5".

It is necessary to completely dismantle this type of column so that the inner tube can be shortened 3.5".

It is necessary to completely dismantle this type of column so that the inner tube can be shortened 3.5".

Cut column end off and de burr.

Cut column end off and de burr.

Cut column end off and de burr.

Cut column end off and de burr.

Cut column end off and de burr.

Cut column end off and de burr.

Fit mount into place so that it is 2mm to 3 mm (1/8” to 3/16 “) past the location ears on the outside of the column

Fit mount into place so that it is 2mm to 3 mm (1/8” to 3/16 “) past the location ears on the outside of the column

Fit mount into place so that it is 2mm to 3 mm (1/8” to 3/16 “) past the location ears on the outside of the column

Fit mount into place so that it is 2mm to 3 mm (1/8” to 3/16 “) past the location ears on the outside of the column

Fit mount into place so that it is 2mm to 3 mm (1/8” to 3/16 “) past the location ears on the outside of the column

Fit mount into place so that it is 2mm to 3 mm (1/8” to 3/16 “) past the location ears on the outside of the column

Lower column bearing mount

Lower column bearing mount

Lower column bearing mount

Lower column bearing mount

Lower column bearing mount

Lower column bearing mount

Slide RRS lower column internal shaft into bearing housing engaging at least 5" of upper shaft.

Slide RRS lower column internal shaft into bearing housing engaging at least 5" of upper shaft.

Slide RRS lower column internal shaft into bearing housing engaging at least 5" of upper shaft.

Slide RRS lower column internal shaft into bearing housing engaging at least 5" of upper shaft.

Slide RRS lower column internal shaft into bearing housing engaging at least 5" of upper shaft.

Slide RRS lower column internal shaft into bearing housing engaging at least 5" of upper shaft.

STEP 15: Install steering uni's and intermediate shaft. Make sure set screw locates into the slot on shaft

STEP 15: Install steering uni's and intermediate shaft. Make sure set screw locates into the slot on shaft

STEP 15: Install steering uni's and intermediate shaft. Make sure set screw locates into the slot on shaft

STEP 15: Install steering uni's and intermediate shaft. Make sure set screw locates into the slot on shaft

STEP 15: Install steering uni's and intermediate shaft. Make sure set screw locates into the slot on shaft

STEP 15: Install steering uni's and intermediate shaft. Make sure set screw locates into the slot on shaft

Step 16:  torque set screws and nuts to specified settings 32 lb/ft and secure with a thread lock solution such as locktite

Step 16:  torque set screws and nuts to specified settings 32 lb/ft and secure with a thread lock solution such as locktite

Step 16:  torque set screws and nuts to specified settings 32 lb/ft and secure with a thread lock solution such as locktite

Step 16:  torque set screws and nuts to specified settings 32 lb/ft and secure with a thread lock solution such as locktite

Step 16:  torque set screws and nuts to specified settings 32 lb/ft and secure with a thread lock solution such as locktite

Step 16:  torque set screws and nuts to specified settings 32 lb/ft and secure with a thread lock solution such as locktite

Step 17: The universal joint alignment is determined by adjusting the steering column position in the firewall opening.

Step 17: The universal joint alignment is determined by adjusting the steering column position in the firewall opening.

Step 17: The universal joint alignment is determined by adjusting the steering column position in the firewall opening.

Step 17: The universal joint alignment is determined by adjusting the steering column position in the firewall opening.

Step 17: The universal joint alignment is determined by adjusting the steering column position in the firewall opening.

Step 17: The universal joint alignment is determined by adjusting the steering column position in the firewall opening.

If the column is too low or too high in the firewall uni-joint misalignment will occur causing uni joint bind with typical feel of notchiness or a binding spot as the steering wheel is turned.

If the column is too low or too high in the firewall uni-joint misalignment will occur causing uni joint bind with typical feel of notchiness or a binding spot as the steering wheel is turned.

If the column is too low or too high in the firewall uni-joint misalignment will occur causing uni joint bind with typical feel of notchiness or a binding spot as the steering wheel is turned.

If the column is too low or too high in the firewall uni-joint misalignment will occur causing uni joint bind with typical feel of notchiness or a binding spot as the steering wheel is turned.

If the column is too low or too high in the firewall uni-joint misalignment will occur causing uni joint bind with typical feel of notchiness or a binding spot as the steering wheel is turned.

If the column is too low or too high in the firewall uni-joint misalignment will occur causing uni joint bind with typical feel of notchiness or a binding spot as the steering wheel is turned.

Correct uni-joint alignment is achieved when both uni-joints are at the same angle, and that angle is 42.5° or less.

Correct uni-joint alignment is achieved when both uni-joints are at the same angle, and that angle is 42.5° or less.

Correct uni-joint alignment is achieved when both uni-joints are at the same angle, and that angle is 42.5° or less.

Correct uni-joint alignment is achieved when both uni-joints are at the same angle, and that angle is 42.5° or less.

Correct uni-joint alignment is achieved when both uni-joints are at the same angle, and that angle is 42.5° or less.

Correct uni-joint alignment is achieved when both uni-joints are at the same angle, and that angle is 42.5° or less.

Step 18:  Set wheel alignment and road test.

Step 18:  Set wheel alignment and road test.

Step 18:  Set wheel alignment and road test.

Step 18:  Set wheel alignment and road test.

Step 18:  Set wheel alignment and road test.

Step 18:  Set wheel alignment and road test.

Wheel Alignment Guidelines

Wheel Alignment Guidelines

Wheel Alignment Guidelines

Wheel Alignment Guidelines

Wheel Alignment Guidelines

Wheel Alignment Guidelines

Without RRS Strut Conversion

Camber +¼°

Caster +1½°

Toe in 2mm

 

Without RRS Strut Conversion

Camber +¼°

Caster +1½°

Toe in 2mm

 

Without RRS Strut Conversion

Camber +¼°

Caster +1½°

Toe in 2mm

 

Without RRS Strut Conversion

Camber +¼°

Caster +1½°

Toe in 2mm

 

Without RRS Strut Conversion

Camber +¼°

Caster +1½°

Toe in 2mm

 

Without RRS Strut Conversion

Camber +¼°

Caster +1½°

Toe in 2mm

 

Caster should be calculated with the following turntable position

Toe out on turns.  With the inner wheel at 20° outer wheel 17°to 18°(note some wheel alignment machines use different toe out on turns setting: - therefore caster angle requirements may be reduced 1°to 1 ½ ° to obtain accurate track on turns).

Caster should be calculated with the following turntable position

Toe out on turns.  With the inner wheel at 20° outer wheel 17°to 18°(note some wheel alignment machines use different toe out on turns setting: - therefore caster angle requirements may be reduced 1°to 1 ½ ° to obtain accurate track on turns).

Caster should be calculated with the following turntable position

Toe out on turns.  With the inner wheel at 20° outer wheel 17°to 18°(note some wheel alignment machines use different toe out on turns setting: - therefore caster angle requirements may be reduced 1°to 1 ½ ° to obtain accurate track on turns).

Caster should be calculated with the following turntable position

Toe out on turns.  With the inner wheel at 20° outer wheel 17°to 18°(note some wheel alignment machines use different toe out on turns setting: - therefore caster angle requirements may be reduced 1°to 1 ½ ° to obtain accurate track on turns).

Caster should be calculated with the following turntable position

Toe out on turns.  With the inner wheel at 20° outer wheel 17°to 18°(note some wheel alignment machines use different toe out on turns setting: - therefore caster angle requirements may be reduced 1°to 1 ½ ° to obtain accurate track on turns).

Caster should be calculated with the following turntable position

Toe out on turns.  With the inner wheel at 20° outer wheel 17°to 18°(note some wheel alignment machines use different toe out on turns setting: - therefore caster angle requirements may be reduced 1°to 1 ½ ° to obtain accurate track on turns).

Fitting an RRS GT rack will keep your stock turning circle of your classic ford except XK-XP Falcons & 66-68 Mustangs that do not use the RRS strut front end (the turning circle may increase by less than 8%).

Fitting an RRS GT rack will keep your stock turning circle of your classic ford except XK-XP Falcons & 66-68 Mustangs that do not use the RRS strut front end (the turning circle may increase by less than 8%).

Fitting an RRS GT rack will keep your stock turning circle of your classic ford except XK-XP Falcons & 66-68 Mustangs that do not use the RRS strut front end (the turning circle may increase by less than 8%).

Fitting an RRS GT rack will keep your stock turning circle of your classic ford except XK-XP Falcons & 66-68 Mustangs that do not use the RRS strut front end (the turning circle may increase by less than 8%).

Fitting an RRS GT rack will keep your stock turning circle of your classic ford except XK-XP Falcons & 66-68 Mustangs that do not use the RRS strut front end (the turning circle may increase by less than 8%).

Fitting an RRS GT rack will keep your stock turning circle of your classic ford except XK-XP Falcons & 66-68 Mustangs that do not use the RRS strut front end (the turning circle may increase by less than 8%).

Warranty is void, if the warranty card is not completed correctly by a qualified wheel alignment specialist.

Warranty is void, if the warranty card is not completed correctly by a qualified wheel alignment specialist.

Warranty is void, if the warranty card is not completed correctly by a qualified wheel alignment specialist.

Warranty is void, if the warranty card is not completed correctly by a qualified wheel alignment specialist.

Warranty is void, if the warranty card is not completed correctly by a qualified wheel alignment specialist.

Warranty is void, if the warranty card is not completed correctly by a qualified wheel alignment specialist.

Safe driving and road worthiness is the responsibility of the installer and wheel alignment specialist, to be completely roadworthy and warranty valid.

 

The warranty check-list must be filled out by the wheel alignment specialist and returned to RRS head office.

Safe driving and road worthiness is the responsibility of the installer and wheel alignment specialist, to be completely roadworthy and warranty valid.

 

The warranty check-list must be filled out by the wheel alignment specialist and returned to RRS head office.

Safe driving and road worthiness is the responsibility of the installer and wheel alignment specialist, to be completely roadworthy and warranty valid.

 

The warranty check-list must be filled out by the wheel alignment specialist and returned to RRS head office.

Safe driving and road worthiness is the responsibility of the installer and wheel alignment specialist, to be completely roadworthy and warranty valid.

 

The warranty check-list must be filled out by the wheel alignment specialist and returned to RRS head office.

Safe driving and road worthiness is the responsibility of the installer and wheel alignment specialist, to be completely roadworthy and warranty valid.

 

The warranty check-list must be filled out by the wheel alignment specialist and returned to RRS head office.

Safe driving and road worthiness is the responsibility of the installer and wheel alignment specialist, to be completely roadworthy and warranty valid.

 

The warranty check-list must be filled out by the wheel alignment specialist and returned to RRS head office.

RRS strives for trouble free and quality outcomes therefore it is our wish that you will take the time to make any comment about our products and outcome of your particular application

 

WARNING:  Important Note:  Centre bolts that mount drag bar into rack housing should be re-torque at least 3 times e.g. 600 miles (1,000 km) each or every three (3) weeks after installation of RRS rack & pinion to ensure rack slider seating 60 – 65ftlbs    90nm.  For technical assistance contact RRS

 

RRS will void warranty claims that are the result of using a damaged or defective power steering pump.  Warranties are void if thread and bolt seals are disturbed on power head.

RRS strives for trouble free and quality outcomes therefore it is our wish that you will take the time to make any comment about our products and outcome of your particular application

 

WARNING:  Important Note:  Centre bolts that mount drag bar into rack housing should be re-torque at least 3 times e.g. 600 miles (1,000 km) each or every three (3) weeks after installation of RRS rack & pinion to ensure rack slider seating 60 – 65ftlbs    90nm.  For technical assistance contact RRS

 

RRS will void warranty claims that are the result of using a damaged or defective power steering pump.  Warranties are void if thread and bolt seals are disturbed on power head.

RRS strives for trouble free and quality outcomes therefore it is our wish that you will take the time to make any comment about our products and outcome of your particular application

 

WARNING:  Important Note:  Centre bolts that mount drag bar into rack housing should be re-torque at least 3 times e.g. 600 miles (1,000 km) each or every three (3) weeks after installation of RRS rack & pinion to ensure rack slider seating 60 – 65ftlbs    90nm.  For technical assistance contact RRS

 

RRS will void warranty claims that are the result of using a damaged or defective power steering pump.  Warranties are void if thread and bolt seals are disturbed on power head.

RRS strives for trouble free and quality outcomes therefore it is our wish that you will take the time to make any comment about our products and outcome of your particular application

 

WARNING:  Important Note:  Centre bolts that mount drag bar into rack housing should be re-torque at least 3 times e.g. 600 miles (1,000 km) each or every three (3) weeks after installation of RRS rack & pinion to ensure rack slider seating 60 – 65ftlbs    90nm.  For technical assistance contact RRS

 

RRS will void warranty claims that are the result of using a damaged or defective power steering pump.  Warranties are void if thread and bolt seals are disturbed on power head.

RRS strives for trouble free and quality outcomes therefore it is our wish that you will take the time to make any comment about our products and outcome of your particular application

 

WARNING:  Important Note:  Centre bolts that mount drag bar into rack housing should be re-torque at least 3 times e.g. 600 miles (1,000 km) each or every three (3) weeks after installation of RRS rack & pinion to ensure rack slider seating 60 – 65ftlbs    90nm.  For technical assistance contact RRS

 

RRS will void warranty claims that are the result of using a damaged or defective power steering pump.  Warranties are void if thread and bolt seals are disturbed on power head.

RRS strives for trouble free and quality outcomes therefore it is our wish that you will take the time to make any comment about our products and outcome of your particular application

 

WARNING:  Important Note:  Centre bolts that mount drag bar into rack housing should be re-torque at least 3 times e.g. 600 miles (1,000 km) each or every three (3) weeks after installation of RRS rack & pinion to ensure rack slider seating 60 – 65ftlbs    90nm.  For technical assistance contact RRS

 

RRS will void warranty claims that are the result of using a damaged or defective power steering pump.  Warranties are void if thread and bolt seals are disturbed on power head.

Installation Instructions

Installation Instructions

Installation Instructions

Installation Instructions

Installation Instructions

Installation Instructions

RRS Manual Rack & Pinion Steering Kit

RRS Manual Rack & Pinion Steering Kit

RRS Manual Rack & Pinion Steering Kit

RRS Manual Rack & Pinion Steering Kit

RRS Manual Rack & Pinion Steering Kit

RRS Manual Rack & Pinion Steering Kit

RRS lower column shaft, upper uni, intermediate shaft and lower uni.

RRS lower column shaft, upper uni, intermediate shaft and lower uni.

RRS lower column shaft, upper uni, intermediate shaft and lower uni.

RRS lower column shaft, upper uni, intermediate shaft and lower uni.

RRS lower column shaft, upper uni, intermediate shaft and lower uni.

RRS lower column shaft, upper uni, intermediate shaft and lower uni.

RRS lower column shaft, upper uni, intermediate shaft and lower uni.

RRS lower column shaft, upper uni, intermediate shaft and lower uni.

RRS lower column shaft, upper uni, intermediate shaft and lower uni.

RRS lower column shaft, upper uni, intermediate shaft and lower uni.

RRS lower column shaft, upper uni, intermediate shaft and lower uni.

RRS lower column shaft, upper uni, intermediate shaft and lower uni.

"Road Race Science"

(61) 02 9907 3755

US Toll Free 866 597 4662

The inner bearing case must be separated from the outer bearing case, which may require grinding the inner case to enable it to be separated easily.

The inner bearing case must be separated from the outer bearing case, which may require grinding the inner case to enable it to be separated easily.

The inner bearing case must be separated from the outer bearing case, which may require grinding the inner case to enable it to be separated easily.

The inner bearing case must be separated from the outer bearing case, which may require grinding the inner case to enable it to be separated easily.

The inner bearing case must be separated from the outer bearing case, which may require grinding the inner case to enable it to be separated easily.

The inner bearing case must be separated from the outer bearing case, which may require grinding the inner case to enable it to be separated easily.

Lower column bearing mount, being fitted to shortened column.

Lower column bearing mount, being fitted to shortened column.

Lower column bearing mount, being fitted to shortened column.

Lower column bearing mount, being fitted to shortened column.

Lower column bearing mount, being fitted to shortened column.

Lower column bearing mount, being fitted to shortened column.

Lower column bearing mount, being fitted to shortened column.

Lower column bearing mount, being fitted to shortened column.

Lower column bearing mount, being fitted to shortened column.

Lower column bearing mount, being fitted to shortened column.

Lower column bearing mount, being fitted to shortened column.

Lower column bearing mount, being fitted to shortened column.

RRS upper internal column shaft and locater bearing and collar fitted to top of the column.

RRS upper internal column shaft and locater bearing and collar fitted to top of the column.

RRS upper internal column shaft and locater bearing and collar fitted to top of the column.

RRS upper internal column shaft and locater bearing and collar fitted to top of the column.

RRS upper internal column shaft and locater bearing and collar fitted to top of the column.

RRS upper internal column shaft and locater bearing and collar fitted to top of the column.

Slide RRS lower column internal shaft into bearing housing engaging at least 5" of upper shaft.

Slide RRS lower column internal shaft into bearing housing engaging at least 5" of upper shaft.

Slide RRS lower column internal shaft into bearing housing engaging at least 5" of upper shaft.

Slide RRS lower column internal shaft into bearing housing engaging at least 5" of upper shaft.

Slide RRS lower column internal shaft into bearing housing engaging at least 5" of upper shaft.

Slide RRS lower column internal shaft into bearing housing engaging at least 5" of upper shaft.

The upper internal shaft and upper bearing remain unchanged.

The upper internal shaft and upper bearing remain unchanged.

The upper internal shaft and upper bearing remain unchanged.

The upper internal shaft and upper bearing remain unchanged.

The upper internal shaft and upper bearing remain unchanged.

The upper internal shaft and upper bearing remain unchanged.

The end of the outer column that protrudes through the firewall must be shortened 1 ½ inches

The end of the outer column that protrudes through the firewall must be shortened 1 ½ inches

The end of the outer column that protrudes through the firewall must be shortened 1 ½ inches

The end of the outer column that protrudes through the firewall must be shortened 1 ½ inches

The end of the outer column that protrudes through the firewall must be shortened 1 ½ inches

The end of the outer column that protrudes through the firewall must be shortened 1 ½ inches

Install RRS support ring for inner tube location.

Install RRS support ring for inner tube location.

Install RRS support ring for inner tube location.

Install RRS support ring for inner tube location.

Install RRS support ring for inner tube location.

Install RRS support ring for inner tube location.

The mount in place should look like this. Then reassemble the entire column ready for the installation of the RRS lower column shaft and bearing mount.

The mount in place should look like this. Then reassemble the entire column ready for the installation of the RRS lower column shaft and bearing mount.

The mount in place should look like this. Then reassemble the entire column ready for the installation of the RRS lower column shaft and bearing mount.

The mount in place should look like this. Then reassemble the entire column ready for the installation of the RRS lower column shaft and bearing mount.

The mount in place should look like this. Then reassemble the entire column ready for the installation of the RRS lower column shaft and bearing mount.

The mount in place should look like this. Then reassemble the entire column ready for the installation of the RRS lower column shaft and bearing mount.

Column end should look like this after installation. Refit steering column, anchor lower column mount in such a way that no universal bind occurs.

Column end should look like this after installation. Refit steering column, anchor lower column mount in such a way that no universal bind occurs.

Column end should look like this after installation. Refit steering column, anchor lower column mount in such a way that no universal bind occurs.

Column end should look like this after installation. Refit steering column, anchor lower column mount in such a way that no universal bind occurs.

Column end should look like this after installation. Refit steering column, anchor lower column mount in such a way that no universal bind occurs.

Column end should look like this after installation. Refit steering column, anchor lower column mount in such a way that no universal bind occurs.

With RRS Strut Conversion

 

Camber -¼°

Caster 3¾ to°4¼°

Toe in 2mm

With RRS Strut Conversion

 

Camber -¼°

Caster 3¾ to°4¼°

Toe in 2mm

With RRS Strut Conversion

 

Camber -¼°

Caster 3¾ to°4¼°

Toe in 2mm

With RRS Strut Conversion

 

Camber -¼°

Caster 3¾ to°4¼°

Toe in 2mm

With RRS Strut Conversion

 

Camber -¼°

Caster 3¾ to°4¼°

Toe in 2mm

With RRS Strut Conversion

 

Camber -¼°

Caster 3¾ to°4¼°

Toe in 2mm

Tighten grub screws to secure in place.

Tighten grub screws to secure in place.

Tighten grub screws to secure in place.

Tighten grub screws to secure in place.

Tighten grub screws to secure in place.

Tighten grub screws to secure in place.

Tighten grub screws to secure in place.

Tighten grub screws to secure in place.

Tighten grub screws to secure in place.

Tighten grub screws to secure in place.

Tighten grub screws to secure in place.

Tighten grub screws to secure in place.

"Road" "Race" "Science"

Installation Instructions

RRS Powered Rack & Pinion Steering Kit

STEP 1: Immobolise Vehicle by disconnecting the battery.

STEP 2: Jack up vehicle on a flat workshop area.

STEP 3: Remove steering column as per factory repair manual.

STEP 4: Remove steering box, ilder arm and drag link as factory repair manual.

STEP 5: Make sure all OEM steering box, Idler arm bolt holes and chassis rails are in good order and free from burs, obstructions or damage.

Important Note Australian Falcon models XB, XC, and XD chassis gusset will require a small amount of trimming to provide adequate clearance for the RRS rack brackets.

STEP 6: Install RRS conversion brackets onto the chassis rails and torque bolts to specified settings.

The Steering box nuts and bolts torque settings are 40ftlbs     55nm.

   The Idler nuts and bolts torque settings are 30ftlbs      38nm.

STEP 7: Using the bracket as a template drill chassis rail edge with a 8mm drill

STEP 8: Fit load spreader plate

The load spreader nuts and bolts torque settings are 18-20ftlbs      22-24nm.

   If you are fitting a powered rack it is easier to fit the hydraulic lines before bolting  the rack in place.

STEP 9: Fit rubber insulators to rack

STEP 10: Fit U clamps around rack rubber and fit to up to rack checking alignment is correct to rack. If rack does not line up stop and call RRS.

STEP 11: Install rack tighten until rack is firm against mounting bracket

STEP 12: Connect tie rod ends making sure adequate thread engagement into sleeve

STEP 13: Tie rod end adjusters must be adjusted to allow equal range of movement (rack is centred).

Note: The RRS rack and pinion has built in steering stops and therefore OEM stops can be deleted

STEP 14: Modify steering column according to the type of column your car has fitted.

Non-collapsible columns

 

Non-collapsible columns have a press fit bearing below the indicator mechanism,

this will require replacement by the RRS top shaft and bearing

Once column is removed, cleaned and dismantled remove top bearing and casing.

RRS upper internal column shaft and locater bearing and collar.

RRS upper internal column shaft and locater bearing and collar fitted to top of the column.

NOTE: on some vehicles steering wheel to blinker housing interference may occur, this can be remedied by either cutting back the die cast blinker shroud or cutting new cir-clip grooves in the steering shaft further down.

Check the base of the column and mark it to be flush with the fire wall.

Cut column to length, de-burr and clean cut, remove scam ridge if necessary.

Lower column bearing mount

RRS lower column shaft, upper uni, intermediate shaft and lower uni.

Slide RRS lower column internal shaft into bearing housing.

Once the column is completely assembled and installed, a lower column support plate, which is provided by RRS, if applicable to your vehicle.  You may need to drill your column support plate and mount it to floor.   This required to be fitted in such a way as to provide a secure anchor point that will correctly align the steering uni’(so as not to cause any universal joint bind)

The column is now ready to fit back into the vehicle.

Double Tube collapsible columns

 

Double tube collapsible columns are most easily identified by a corrugated lower outer column case.

Internally is another telescopic tube through which the steering shaft passes.

It is necessary to completely dismantle this type of column so that the inner tube can be shortened 3.5".

Cut column end off and de burr.

Fit mount into place so that it is 2mm to 3 mm (1/8” to 3/16 “) past the location ears on the outside of the column

Lower column bearing mount

RRS lower column shaft, upper uni, intermediate shaft and lower uni.

Slide RRS lower column internal shaft into bearing housing engaging at least 5" of upper shaft.

STEP 15: Install steering uni's and intermediate shaft. Make sure set screw locates into the slot on shaft

Step 16:  torque set screws and nuts to specified settings 32 lb/ft and secure with a thread lock solution such as locktite

Step 17: The universal joint alignment is determined by adjusting the steering column position in the firewall opening.

If the column is too low or too high in the firewall uni-joint misalignment will occur causing uni joint bind with typical feel of notchiness or a binding spot as the steering wheel is turned.

Correct uni-joint alignment is achieved when both uni-joints are at the same angle, and that angle is 42.5° or less.

Step 18:  Connect hydraulic lines to recommended power steering pump and purge the system of air. Use Ford Motorcraft R1424 power steer hydraulic fluid.

Step 19:  Set wheel alignment and road test.

Wheel Alignment Guidelines

Without RRS Strut Conversion

Camber +¼°

Caster +1½°

Toe in 2mm

 

Caster should be calculated with the following turntable position

Toe out on turns.  With the inner wheel at 20° outer wheel 17°to 18°(note some wheel alignment machines use different toe out on turns setting: - therefore caster angle requirements may be reduced 1°to 1 ½ ° to obtain accurate track on turns).

Fitting an RRS GT rack will keep your stock turning circle of your classic ford except XK-XP Falcons and 1966-68 Mustangs that do not use the RRS strut front end (the turning circle may increase by less than 8%).

Warranty is void, if the warranty card is not completed correctly by a qualified wheel alignment specialist.

Safe driving and road worthiness is the responsibility of the installer and wheel alignment specialist, to be completely roadworthy and warranty valid.

 

The warranty check-list must be filled out by the wheel alignment specialist and returned to RRS head office.

RRS strives for trouble free and quality outcomes therefore it is our wish that you will take the time to make any comment about our products and outcome of your particular application

 

WARNING:  Important Note:  Centre bolts that mount drag bar into rack housing should be re-torque at least 3 times e.g. 600 miles (1,000 km) each or every three (3) weeks after installation of RRS rack & pinion to ensure rack slider seating 60 – 65ftlbs    90nm.  For technical assistance contact RRS

 

RRS will void warranty claims that are the result of using a damaged or defective power steering pump.  Warranties are void if thread and bolt seals are disturbed on power head.

Tighten grub screws to secure in place.

Tighten grub screws to secure in place.

The inner bearing case must be separated from the outer bearing case, which may require grinding the inner case to enable it to be separated easily.

Slide RRS lower column internal shaft into bearing housing engaging at least 5" of upper shaft.

Lower column bearing mount, being fitted to shortened column.

The upper internal shaft and upper bearing remain unchanged.

The end of the outer column that protrudes through the firewall must be shortened 1 ½ inches

Install RRS support ring for inner tube location.

The mount in place should look like this. Then reassemble the entire column ready for the installation of the RRS lower column shaft and bearing mount.

Lower column bearing mount, being fitted to shortened column.

Column end should look like this after installation. Refit steering column, anchor lower column mount in such a way that no universal bind occurs.

With RRS Strut Conversion

 

Camber -¼°

Caster 3¾° to 4¼°

Toe in 2mm

Jack the front wheels up.

Fill reservoir to high point on dip stick. Turn the steering wheel slowly lock to lock. Check the fluid level again, fill again to high point on dip stick. Repeat process adding an extra lock to lock turn each time.

Once you can can turn the wheel lock to lock and the level is unchanged, start the vehicle momentarily.

turn off the vehicle and check level again. Add power steering fluid if the level is low.

Start the car and slowly turn the wheel lock to lock check the level and check for bubbles. Foamy fluid is an indication of air getting into the system. Continue process until level is unchanged and no bubbles appear.

Once level has stabilized,check turning is smooth and system is running quietly, you are ready to take the car for wheel alignment.

Installation Instructions

RRS Powered Rack & Pinion Steering Kit

STEP 1: Immobolise Vehicle by disconnecting the battery.

STEP 2: Jack up vehicle on a flat workshop area.

STEP 3: Remove steering column as per factory repair manual.

STEP 4: Remove steering box, ilder arm and drag link as factory repair manual.

STEP 5: Make sure all OEM steering box, Idler arm bolt holes and chassis rails are in good order and free from burs, obstructions or damage.

Important Note Australian Falcon models XB, XC, and XD chassis gusset will require a small amount of trimming to provide adequate clearance for the RRS rack brackets.

STEP 6: Install RRS conversion brackets onto the chassis rails and torque bolts to specified settings.

The Steering box nuts and bolts torque settings are 40ftlbs     55nm.

   The Idler nuts and bolts torque settings are 30ftlbs      38nm.

STEP 7: Using the bracket as a template drill chassis rail edge with a 8mm drill

STEP 8: Fit load spreader plate

The load spreader nuts and bolts torque settings are 18-20ftlbs      22-24nm.

   If you are fitting a powered rack it is easier to fit the hydraulic lines before bolting  the rack in place.

STEP 9: Fit rubber insulators to rack

STEP 10: Fit U clamps around rack rubber and fit to up to rack checking alignment is correct to rack. If rack does not line up stop and call RRS.

STEP 11: Install rack tighten until rack is firm against mounting bracket

STEP 12: Connect tie rod ends making sure adequate thread engagement into sleeve

STEP 13: Tie rod end adjusters must be adjusted to allow equal range of movement (rack is centred).

Note: The RRS rack and pinion has built in steering stops and therefore OEM stops can be deleted

STEP 14: Modify steering column according to the type of column your car has fitted.

Non-collapsible columns

 

Non-collapsible columns have a press fit bearing below the indicator mechanism,

this will require replacement by the RRS top shaft and bearing

Once column is removed, cleaned and dismantled remove top bearing and casing.

The inner bearing case must be separated from the outer bearing case, which may require grinding the inner case to enable it to be separated easily.

RRS upper internal column shaft and locater bearing and collar.

RRS upper internal column shaft and locater bearing and collar fitted to top of the column.

NOTE: on some vehicles steering wheel to blinker housing interference may occur, this can be remedied by either cutting back the die cast blinker shroud or cutting new cir-clip grooves in the steering shaft further down.

Check the base of the column and mark it to be flush with the fire wall.

Cut column to length, de-burr and clean cut, remove scam ridge if necessary.

Lower column bearing mount

Lower column bearing mount, being fitted to shortened column.

Tighten grub screws to secure in place.

RRS lower column shaft, upper uni, intermediate shaft and lower uni.

Slide RRS lower column internal shaft into bearing housing.

Slide RRS lower column internal shaft into bearing housing engaging at least 5" of upper shaft.

Once the column is completely assembled and installed, a lower column support plate, which is provided by RRS, if applicable to your vehicle.  You may need to drill your column support plate and mount it to floor.   This required to be fitted in such a way as to provide a secure anchor point that will correctly align the steering uni’(so as not to cause any universal joint bind)

The column is now ready to fit back into the vehicle.

Double Tube collapsible columns

 

Double tube collapsible columns are most easily identified by a corrugated lower outer column case.

Internally is another telescopic tube through which the steering shaft passes.

The upper internal shaft and upper bearing remain unchanged.

It is necessary to completely dismantle this type of column so that the inner tube can be shortened 3.5".

The end of the outer column that protrudes through the firewall must be shortened 1 ½ inches

Install RRS support ring for inner tube location.

Fit mount into place so that it is 2mm to 3 mm (1/8” to 3/16 “) past the location ears on the outside of the column

The mount in place should look like this. Then reassemble the entire column ready for the installation of the RRS lower column shaft and bearing mount.

Tighten grub screws to secure in place.

RRS lower column shaft, upper uni, intermediate shaft and lower uni.

Slide RRS lower column internal shaft into bearing housing engaging at least 5" of upper shaft.

Column end should look like this after installation. Refit steering column, anchor lower column mount in such a way that no universal bind occurs.

STEP 15: Install steering uni's and intermediate shaft. Make sure set screw locates into the slot on shaft

Step 16:  torque set screws and nuts to specified settings 32 lb/ft and secure with a thread lock solution such as locktite

Step 17: The universal joint alignment is determined by adjusting the steering column position in the firewall opening.

If the column is too low or too high in the firewall uni-joint misalignment will occur causing uni joint bind with typical feel of notchiness or a binding spot as the steering wheel is turned.

Correct uni-joint alignment is achieved when both uni-joints are at the same angle, and that angle is 42.5° or less.

Step 18:  Connect hydraulic lines to recommended power steering pump and purge the system of air. Use Ford Motorcraft R1424 power steer hydraulic fluid.

Jack the front wheels up.

Fill reservoir to high point on dip stick. Turn the steering wheel slowly lock to lock. Check the fluid level again, fill again to high point on dip stick. Repeat process adding an extra lock to lock turn each time.

Once you can can turn the wheel lock to lock and the level is unchanged, start the vehicle momentarily.

turn off the vehicle and check level again. Add power steering fluid if the level is low.

Start the car and slowly turn the wheel lock to lock check the level and check for bubbles. Foamy fluid is an indication of air getting into the system. Continue process until level is unchanged and no bubbles appear.

Once level has stabilized,check turning is smooth and system is running quietly, you are ready to take the car for wheel alignment.

Step 19:  Set wheel alignment and road test.

Wheel Alignment Guidelines

Without RRS Strut Conversion

Camber +¼°

Caster +1½°

Toe in 2mm

 

Caster should be calculated with the following turntable position

Toe out on turns.  With the inner wheel at 20° outer wheel 17°to 18°(note some wheel alignment machines use different toe out on turns setting: - therefore caster angle requirements may be reduced 1°to 1 ½ ° to obtain accurate track on turns).

Fitting an RRS GT rack will keep your stock turning circle of your classic ford except XK-XP Falcons and 1966-68 Mustangs that do not use the RRS strut front end (the turning circle may increase by less than 8%).

Warranty is void, if the warranty card is not completed correctly by a qualified wheel alignment specialist.

Safe driving and road worthiness is the responsibility of the installer and wheel alignment specialist, to be completely roadworthy and warranty valid.

 

The warranty check-list must be filled out by the wheel alignment specialist and returned to RRS head office.

RRS strives for trouble free and quality outcomes therefore it is our wish that you will take the time to make any comment about our products and outcome of your particular application

 

WARNING:  Important Note:  Centre bolts that mount drag bar into rack housing should be re-torque at least 3 times e.g. 600 miles (1,000 km) each or every three (3) weeks after installation of RRS rack & pinion to ensure rack slider seating 60 – 65ftlbs    90nm.  For technical assistance contact RRS

 

RRS will void warranty claims that are the result of using a damaged or defective power steering pump.  Warranties are void if thread and bolt seals are disturbed on power head.

Cut column end off and de burr.

Lower column bearing mount

Lower column bearing mount, being fitted to shortened column.

With RRS Strut Conversion

 

Camber -¼°

Caster 3¾° to 4¼°

Toe in 2mm

Installation Instructions

RRS Powered Rack & Pinion Steering Kit

STEP 1: Immobolise Vehicle by disconnecting the battery.

STEP 2: Jack up vehicle on a flat workshop area.

STEP 3: Remove steering column as per factory repair manual.

STEP 4: Remove steering box, ilder arm and drag link as factory repair manual.

STEP 5: Make sure all OEM steering box, Idler arm bolt holes and chassis rails are in good order and free from burs, obstructions or damage.

Important Note Australian Falcon models XB, XC, and XD chassis gusset will require a small amount of trimming to provide adequate clearance for the RRS rack brackets.

STEP 6: Install RRS conversion brackets onto the chassis rails and torque bolts to specified settings.

The Steering box nuts and bolts torque settings are 40ftlbs     55nm.

   The Idler nuts and bolts torque settings are 30ftlbs      38nm.

STEP 7: Using the bracket as a template drill chassis rail edge with a 8mm drill

STEP 8: Fit load spreader plate

The load spreader nuts and bolts torque settings are 18-20ftlbs      22-24nm.

   If you are fitting a powered rack it is easier to fit the hydraulic lines before bolting  the rack in place.

STEP 9: Fit rubber insulators to rack

STEP 10: Fit U clamps around rack rubber and fit to up to rack checking alignment is correct to rack. If rack does not line up stop and call RRS.

STEP 11: Install rack tighten until rack is firm against mounting bracket

STEP 12: Connect tie rod ends making sure adequate thread engagement into sleeve

STEP 13: Tie rod end adjusters must be adjusted to allow equal range of movement (rack is centred).

Note: The RRS rack and pinion has built in steering stops and therefore OEM stops can be deleted

STEP 14: Modify steering column according to the type of column your car has fitted.

Non-collapsible columns

 

Non-collapsible columns have a press fit bearing below the indicator mechanism,

this will require replacement by the RRS top shaft and bearing

Once column is removed, cleaned and dismantled remove top bearing and casing.

The inner bearing case must be separated from the outer bearing case, which may require grinding the inner case to enable it to be separated easily.

RRS upper internal column shaft and locater bearing and collar.

RRS upper internal column shaft and locater bearing and collar fitted to top of the column.

NOTE: on some vehicles steering wheel to blinker housing interference may occur, this can be remedied by either cutting back the die cast blinker shroud or cutting new cir-clip grooves in the steering shaft further down.

Check the base of the column and mark it to be flush with the fire wall.

Cut column to length, de-burr and clean cut, remove scam ridge if necessary.

Lower column bearing mount

Lower column bearing mount, being fitted to shortened column.

Tighten grub screws to secure in place.

RRS lower column shaft, upper uni, intermediate shaft and lower uni.

Slide RRS lower column internal shaft into bearing housing.

Slide RRS lower column internal shaft into bearing housing engaging at least 5" of upper shaft.

Once the column is completely assembled and installed, a lower column support plate, which is provided by RRS, if applicable to your vehicle.  You may need to drill your column support plate and mount it to floor.   This required to be fitted in such a way as to provide a secure anchor point that will correctly align the steering uni’(so as not to cause any universal joint bind)

The column is now ready to fit back into the vehicle.

Double Tube collapsible columns

 

Double tube collapsible columns are most easily identified by a corrugated lower outer column case.

Internally is another telescopic tube through which the steering shaft passes.

The upper internal shaft and upper bearing remain unchanged.

It is necessary to completely dismantle this type of column so that the inner tube can be shortened 3.5".

The end of the outer column that protrudes through the firewall must be shortened 1 ½ inches

Install RRS support ring for inner tube location.

Fit mount into place so that it is 2mm to 3 mm (1/8” to 3/16 “) past the location ears on the outside of the column

The mount in place should look like this. Then reassemble the entire column ready for the installation of the RRS lower column shaft and bearing mount.

Tighten grub screws to secure in place.

RRS lower column shaft, upper uni, intermediate shaft and lower uni.

Slide RRS lower column internal shaft into bearing housing engaging at least 5" of upper shaft.

Column end should look like this after installation. Refit steering column, anchor lower column mount in such a way that no universal bind occurs.

STEP 15: Install steering uni's and intermediate shaft. Make sure set screw locates into the slot on shaft

Step 16:  torque set screws and nuts to specified settings 32 lb/ft and secure with a thread lock solution such as locktite

Step 17: The universal joint alignment is determined by adjusting the steering column position in the firewall opening.

If the column is too low or too high in the firewall uni-joint misalignment will occur causing uni joint bind with typical feel of notchiness or a binding spot as the steering wheel is turned.

Correct uni-joint alignment is achieved when both uni-joints are at the same angle, and that angle is 42.5° or less.

Step 18:  Connect hydraulic lines to recommended power steering pump and purge the system of air. Use Ford Motorcraft R1424 power steer hydraulic fluid.

Jack the front wheels up.

Fill reservoir to high point on dip stick. Turn the steering wheel slowly lock to lock. Check the fluid level again, fill again to high point on dip stick. Repeat process adding an extra lock to lock turn each time.

Once you can can turn the wheel lock to lock and the level is unchanged, start the vehicle momentarily.

turn off the vehicle and check level again. Add power steering fluid if the level is low.

Start the car and slowly turn the wheel lock to lock check the level and check for bubbles. Foamy fluid is an indication of air getting into the system. Continue process until level is unchanged and no bubbles appear.

Once level has stabilized,check turning is smooth and system is running quietly, you are ready to take the car for wheel alignment.

Step 19:  Set wheel alignment and road test.

Wheel Alignment Guidelines

Without RRS Strut Conversion

Camber +¼°

Caster +1½°

Toe in 2mm

 

Caster should be calculated with the following turntable position

Toe out on turns.  With the inner wheel at 20° outer wheel 17°to 18°(note some wheel alignment machines use different toe out on turns setting: - therefore caster angle requirements may be reduced 1°to 1 ½ ° to obtain accurate track on turns).

Fitting an RRS GT rack will keep your stock turning circle of your classic ford except XK-XP Falcons and 1966-68 Mustangs that do not use the RRS strut front end (the turning circle may increase by less than 8%).

Warranty is void, if the warranty card is not completed correctly by a qualified wheel alignment specialist.

Safe driving and road worthiness is the responsibility of the installer and wheel alignment specialist, to be completely roadworthy and warranty valid.

 

The warranty check-list must be filled out by the wheel alignment specialist and returned to RRS head office.

RRS strives for trouble free and quality outcomes therefore it is our wish that you will take the time to make any comment about our products and outcome of your particular application

 

WARNING:  Important Note:  Centre bolts that mount drag bar into rack housing should be re-torque at least 3 times e.g. 600 miles (1,000 km) each or every three (3) weeks after installation of RRS rack & pinion to ensure rack slider seating 60 – 65ftlbs    90nm.  For technical assistance contact RRS

 

RRS will void warranty claims that are the result of using a damaged or defective power steering pump.  Warranties are void if thread and bolt seals are disturbed on power head.

Cut column end off and de burr.

Lower column bearing mount, being fitted to shortened column.

Lower column bearing mount

With RRS Strut Conversion

 

Camber -¼°

Caster 3¾° to 4¼°

Toe in 2mm

Step 16:  torque set screws and nuts to specified settings 32 lb/ft and secure with a thread lock solution such as locktite

Step 17: The universal joint alignment is determined by adjusting the steering column position in the firewall opening.

If the column is too low or too high in the firewall uni-joint misalignment will occur causing uni joint bind with typical feel of notchiness or a binding spot as the steering wheel is turned.

Correct uni-joint alignment is achieved when both uni-joints are at the same angle, and that angle is 42.5° or less.

Step 18:  Connect hydraulic lines to recommended power steering pump and purge the system of air. Use Ford Motorcraft R1424 power steer hydraulic fluid.

Jack the front wheels up.

Fill reservoir to high point on dip stick. Turn the steering wheel slowly lock to lock. Check the fluid level again, fill again to high point on dip stick. Repeat process adding an extra lock to lock turn each time.

Once you can can turn the wheel lock to lock and the level is unchanged, start the vehicle momentarily.

turn off the vehicle and check level again. Add power steering fluid if the level is low.

Start the car and slowly turn the wheel lock to lock check the level and check for bubbles. Foamy fluid is an indication of air getting into the system. Continue process until level is unchanged and no bubbles appear.

Once level has stabilized,check turning is smooth and system is running quietly, you are ready to take the car for wheel alignment.

Step 19:  Set wheel alignment and road test.

Wheel Alignment Guidelines

Without RRS Strut Conversion

Camber +¼°

Caster +1½°

Toe in 2mm

 

Caster should be calculated with the following turntable position

Toe out on turns.  With the inner wheel at 20° outer wheel 17°to 18°(note some wheel alignment machines use different toe out on turns setting: - therefore caster angle requirements may be reduced 1°to 1 ½ ° to obtain accurate track on turns).

Fitting an RRS GT rack will keep your stock turning circle of your classic ford except XK-XP Falcons and 1966-68 Mustangs that do not use the RRS strut front end (the turning circle may increase by less than 8%).

Warranty is void, if the warranty card is not completed correctly by a qualified wheel alignment specialist.

Safe driving and road worthiness is the responsibility of the installer and wheel alignment specialist, to be completely roadworthy and warranty valid.

 

The warranty check-list must be filled out by the wheel alignment specialist and returned to RRS head office.

RRS strives for trouble free and quality outcomes therefore it is our wish that you will take the time to make any comment about our products and outcome of your particular application

 

WARNING:  Important Note:  Centre bolts that mount drag bar into rack housing should be re-torque at least 3 times e.g. 600 miles (1,000 km) each or every three (3) weeks after installation of RRS rack & pinion to ensure rack slider seating 60 – 65ftlbs    90nm.  For technical assistance contact RRS

 

RRS will void warranty claims that are the result of using a damaged or defective power steering pump.  Warranties are void if thread and bolt seals are disturbed on power head.

Installation Instructions

RRS Powered Rack & Pinion Steering Kit

STEP 1: Immobolise Vehicle by disconnecting the battery.

STEP 2: Jack up vehicle on a flat workshop area.

STEP 3: Remove steering column as per factory repair manual.

STEP 4: Remove steering box, ilder arm and drag link as factory repair manual.

STEP 5: Make sure all OEM steering box, Idler arm bolt holes and chassis rails are in good order and free from burs, obstructions or damage.

Important Note Australian Falcon models XB, XC, and XD chassis gusset will require a small amount of trimming to provide adequate clearance for the RRS rack brackets.

STEP 6: Install RRS conversion brackets onto the chassis rails and torque bolts to specified settings.

The Steering box nuts and bolts torque settings are 40ftlbs     55nm.

   The Idler nuts and bolts torque settings are 30ftlbs      38nm.

STEP 7: Using the bracket as a template drill chassis rail edge with a 8mm drill

STEP 8: Fit load spreader plate

The load spreader nuts and bolts torque settings are 18-20ftlbs      22-24nm.

   If you are fitting a powered rack it is easier to fit the hydraulic lines before bolting  the rack in place.

STEP 9: Fit rubber insulators to rack

STEP 10: Fit U clamps around rack rubber and fit to up to rack checking alignment is correct to rack. If rack does not line up stop and call RRS.

STEP 11: Install rack tighten until rack is firm against mounting bracket

STEP 12: Connect tie rod ends making sure adequate thread engagement into sleeve

STEP 13: Tie rod end adjusters must be adjusted to allow equal range of movement (rack is centred).

Note: The RRS rack and pinion has built in steering stops and therefore OEM stops can be deleted

STEP 14: Modify steering column according to the type of column your car has fitted.

Non-collapsible columns

 

Non-collapsible columns have a press fit bearing below the indicator mechanism,

this will require replacement by the RRS top shaft and bearing

Once column is removed, cleaned and dismantled remove top bearing and casing.

The inner bearing case must be separated from the outer bearing case, which may require grinding the inner case to enable it to be separated easily.

RRS upper internal column shaft and locater bearing and collar.

RRS upper internal column shaft and locater bearing and collar fitted to top of the column.

NOTE: on some vehicles steering wheel to blinker housing interference may occur, this can be remedied by either cutting back the die cast blinker shroud or cutting new cir-clip grooves in the steering shaft further down.

Check the base of the column and mark it to be flush with the fire wall.

Cut column to length, de-burr and clean cut, remove scam ridge if necessary.

Lower column bearing mount

Lower column bearing mount, being fitted to shortened column.

Tighten grub screws to secure in place.

RRS lower column shaft, upper uni, intermediate shaft and lower uni.

Slide RRS lower column internal shaft into bearing housing.

Slide RRS lower column internal shaft into bearing housing engaging at least 5" of upper shaft.

Once the column is completely assembled and installed, a lower column support plate, which is provided by RRS, if applicable to your vehicle.  You may need to drill your column support plate and mount it to floor.   This required to be fitted in such a way as to provide a secure anchor point that will correctly align the steering uni’(so as not to cause any universal joint bind)

The column is now ready to fit back into the vehicle.

Double Tube collapsible columns

 

Double tube collapsible columns are most easily identified by a corrugated lower outer column case.

Internally is another telescopic tube through which the steering shaft passes.

The upper internal shaft and upper bearing remain unchanged.

It is necessary to completely dismantle this type of column so that the inner tube can be shortened 3.5".

The end of the outer column that protrudes through the firewall must be shortened 1 ½ inches

Cut column end off and de burr.

Install RRS support ring for inner tube location.

Fit mount into place so that it is 2mm to 3 mm (1/8” to 3/16 “) past the location ears on the outside of the column

The mount in place should look like this. Then reassemble the entire column ready for the installation of the RRS lower column shaft and bearing mount.

Lower column bearing mount

Lower column bearing mount, being fitted to shortened column.

Tighten grub screws to secure in place.

RRS lower column shaft, upper uni, intermediate shaft and lower uni.

Slide RRS lower column internal shaft into bearing housing engaging at least 5" of upper shaft.

Column end should look like this after installation. Refit steering column, anchor lower column mount in such a way that no universal bind occurs.

STEP 15: Install steering uni's and intermediate shaft. Make sure set screw locates into the slot on shaft

With RRS Strut Conversion

 

Camber -¼°

Caster 3¾° to 4¼°

Toe in 2mm