Hello,
As the title says I'm having trouble with my rack swap. I'm using a AW111 rack and mk3 intermediate shaft. Using power steering inners and outers and using the t3 manual spacers. Well one side is at full lock and the other side there is no way it is going to go into the steering knuckle, (also t3 zero Ackerman.) I'm thinking I need to remove the spacers. Any suggestions would be appreciated not sure how to post pictures on here i can send emails or I'm on Instagram TheMcKibbin is my handle.

i've done the manual rack conversion but still not sure I follow. Did you re-center the rack (here's the important bit) on the car with the spacer included? By T3 spacer I assume you mean their high steering angle spacer? The AW11 rack sits differently than the AE86 PS rack so basically the outer tie rods aren't going to be evenly threaded on both sides into the inner tie rods. From what i gather that seems to be the issue you're having.

To post pics, first upload them to something like shutterfly and then copy the link from shutterfly into the forum.

-Aaron

Hey man I figured out the problem. The T3 outer tie rods are substantially longer than the OEM ones so I replaced my inner rods with a shorter set and that fixed the issue no more issues! Much appreciated.

I believe you are supposed to use manual rack specific inner tie rods

I'm about to do the same conversion, aw11 manual rack, space adapter, intermediate shaft, manual inner and out rods, ect.

I was wondering if I can change out the intermediate shaft without removing the main steering shaft, how have you guys gone about this? I've read the process in my service manual but it doesn't seem to say.

Do I need to get new claw washers and what does the manual mean when it says to "steak them"?

Also one of my dust boots is toast from my headers blowing out and falling on it a couple years back. What replacement boots work?

Anything else I should look out for or something?

Thanks a bunch, Kedar

How about a good old fashioned alignment at a shop?

Ive done this swap as well. I'm not sure about exact tie rods but the inners for AW11, AE86 power and AE86 manual are different in lengths.

I got it all to work just fine. Swap was easier than I thought it would be. Intermediate shaft slips out with a few hits with a mallet. mr2 boots and new washers tapped to an angle.