Outer Limits 4x4 Board

I thought my steering box was shagged because I was getting quite a lot of freeplay in the steering so I used the info on here to adjust the box but at the time of adjusment I realised that the freeplay was coming from elsewhere, and I identified the problem.



The shaft connecting the steering wheel to the box has a section in the middle where two parts of the shaft (A and B) connect. In effect, shaft A slides into shaft B and probably goes in about 10cm or so. I couldn't tell exactly. Shaft A and B and square (not round) at the ends where they connect which obviously prevents them from spinning on each other, however, when I grab the area where they join, I can shake it and it's definately not a tight connection. I can tell visually that this is what is causing the freeplay. Imagine a square pipe with another square pipe slid inside it where the inside pipe is a little too small. Sure, it can't rotate completely but it will move.

What is the solution to this problem? Is there a reason that this is not a fixed or welded connection? For those with mechanical experience, I hope you can help me out. I'd like to fix it myself because it all looks very simply. Perhaps I should just wedge some folded alluminium can into the gaps to stop the inner shaft moving inside the second.

Thanks for any help.

Regards, Drew.

it should have spot welds holding the two together.. id say these have sheered off and it has worn either shaft to cause the play as these should be tight as.


in a accident those spot welds break causing the shaft to slip into itself instead of the steering wheel pushing into your throat.

Someone has bashed off or on a steering wheel cause it was frozen on the spline.. Thats my guess.

lol i like mark's description... ehehehe optimistic! =)

Hehe sounds about right because (not included on the detailed diagram) there are two holes on one of the sides of shaft B which kinda look like screw holes but they didn't really go anywhere because shaft A was right below them. I'll sort something about. Bit hard to get in there to weld it but I'll see what I can do.

Thanks alot guys. Ya al rok!

those holes actually have nylon melted into them to take up the play,they are overlaped about 3in ,it is a collapsabe shaft so u don't get speared by the steering column in an accident.
most people tack weld them together when the nylon gets broken or melted out to change the length of the shaft for bodylifts or p/s conversions.
is your zuk 92 93on if so you can use the steering column out of a 89 or earlyer zuk that has a colapsable column instead of a colapsabe shaft if you weld the shaft.

hope this helps
Drew