Having just tackled this job the hard way (complete removal and renovation
of column and rack), I can tell you what I found. The worst wear was in
the rubber couplings as you found. In my case the rack was OK after a
cleaning/degreasing and some modern lubrication. A trouble spot is the
pinion gear and the rack itself, as well as where it attaches to the frame
on the TR4A. If the pinion gear and the rack gears show extensive wear
you will need to rebuild the rack and replace the pinion gear. On the TR4
the rack attachment points are U-bolts through aluminum adaptors. On the
4A the set up is different with rubber instead of aluminum leading to a
more sloppy linkage that is worthy of double checking for looseness and
wear etc. It is not difficult to remove the rack and the rubber boots for
an inspection. For good measure replace the boots carefully and
preferably with new ones because if the 35 year old ones haven't
disintegrated yet they will soon.
On the column itself, the easy way to renovate the rubber
couplings would be to remove the lower steering column and rebuild
it on the bench. To do this first loosen the small nut on a
bracket holding the coupling to the splined end of the upper column
section (the part attached to the steering wheel). With some liquid
wrench, a propane torch and some gentle hammering the spline should free
up. Then put the front end on jackstands and do the same thing with the
bracket that attaches to the rack and pinion. You'll probably need a bit
of degreasing to get this out, but when you do you can remove the entire
lower column with the two rubber couplings as one piece. Then its a
simple matter to cut away the wires and remove the bolts and couplings.
When you rebuild it use stainless steel or galvanized automotive wire to
wrap the coupling as original as a safety measure.
While your in there you might want to go under the dash and
tighten up the bolts that secure the upper column to the firewall, and
check that the bracket that is welded to the firewall is not rusted out
and in need of repair. All of these things if loose or rusted can
contribute to sloppy steering linkage. The upper column is collapasible
as an additional safety feature, but no amount of heat could break mine
free into its two sections, probably rusted solid inside.
-Kevin
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