Upgrading the steering system in a classic American vehicle requires precision, technical knowledge, and a focus on compatibility with original equipment. Flaming River, a manufacturer based in the United States, has developed a range of rack-and-pinion systems designed to enhance steering performance while maintaining the integrity of the original vehicle design. This guide draws from firsthand installation experiences, manufacturer documentation, and user reports to provide a detailed overview of the installation process, key components, and considerations for users seeking to install a Flaming River rack-and-pinion system.
Understanding the Flaming River Rack-and-Pinion System
A rack-and-pinion steering system is a mechanical design that converts the rotational movement of the steering wheel into linear motion to turn the wheels. This system is known for its direct response, reduced maintenance, and improved road feedback compared to older recirculating ball systems. Flaming River's rack-and-pinion kits are engineered to fit a variety of classic vehicles, including models like the ’68 Chevrolet C10 and ’79–’93 Fox-Body Mustangs.
The system includes a cradle-mounting assembly that fits between the frame rails of the vehicle. It is constructed with 3/8-inch thick steel mounting plates, designed to reinforce the chassis without requiring cutting, welding, or drilling. This ensures a clean and reliable installation while preserving the original structure of the vehicle.
The hydraulic power-assisted version of the system includes a power-steering pump, a fluid reservoir, and a set of pressure and return hoses. The pump used is a variable-pressure stage-II model that includes a built-in bypass. At higher engine RPM, this bypass reduces pressure and flow, improving response and feedback at high speeds. At low speeds, the pump provides maximum pressure and flow for enhanced power assist during maneuvers such as parking and turning in tight spaces.
The die-cast housing of the rack is designed to maintain the same line position as the original equipment, ensuring compatibility with existing components. The system also features an adjustable pinion housing with a 12:1 gear ratio, allowing for fine-tuning of steering characteristics. This level of adjustability is a key feature that appeals to professional builders and DIY enthusiasts alike.
Components and Kit Contents
Flaming River rack-and-pinion kits are designed to be comprehensive, including all necessary parts for installation. Depending on the model, kits may include:
- Cradle-Mounting Assembly: A pre-fabricated mounting cradle that fits between the frame rails without requiring modification to the vehicle's structure.
- Rack-and-Pinion Unit: The core steering mechanism, complete with internal gears and hydraulic components for power-assisted models.
- Mounting Plates and Hardware: Pre-drilled and sized to align with the original mounting holes where the steering box and idler arm were removed.
- Power Steering Pump and Reservoir (for power-assisted models): A variable-pressure stage-II pump with a built-in bypass system and a fluid reservoir for proper hydraulic function.
- Hose Kit: Pressure and return hoses that connect the power steering pump to the rack unit.
- Universal Joints and Intermediate Shaft: Used to route the steering column linkage from the steering wheel to the rack.
- Swivel Floor Mount: A component that attaches the steering column to the firewall and ensures proper alignment with the dash.
- Instruction Sheet: A detailed guide outlining the installation steps, including bleeding the system and adjusting tie rods.
Additional parts such as tie rod ends, spindles, and steering wheels may be required depending on the specific application and the condition of the original components.
Installation Process Overview
The installation of a Flaming River rack-and-pinion system is a multi-step process that requires careful planning, precision, and attention to detail. Below is a step-by-step breakdown of the typical installation process, based on documented experiences and manufacturer guidance.
Pre-Installation Preparation
Before beginning the installation, it is essential to prepare the vehicle and gather all necessary tools and components. This includes:
- Raising the Vehicle: The vehicle should be securely supported on jackstands to allow access to the undercarriage.
- Marking Measurements: To ensure proper alignment after installation, the distance between the front and back brake rotors should be measured. This helps determine the amount of toe in the current setup, which can be used as a reference point for adjustment.
- Keeping the Steering Wheel Straight: To avoid the need for realignment after installation, the steering wheel should be kept in its original position. This involves ensuring that the wheels are straight and the steering column is not moved until the new system is in place.
- Removing the Wheels: Removing the wheels provides better access to the steering components and allows for the removal of the old system.
Removing the Old System
The first step in the installation is the removal of the existing steering system. This typically involves:
- Removing the Tie Rod Ends: The tie rod ends must be disconnected from the spindles and the steering box. It is important to note the depth at which the tie rod ends were seated to ensure that the new rack is installed with the same alignment.
- Removing the Steering Box and Idler Arm: The original steering box and idler arm are removed using the original mounting holes, which will be reused for the new system.
- Removing the Steering Column Linkage: The universal joints and intermediate shaft connecting the steering column to the steering box are removed. These components are typically replaced with new ones included in the Flaming River kit.
Installing the New Rack-and-Pinion System
Once the old system is removed, the new Flaming River rack-and-pinion unit can be installed. The steps include:
- Positioning the Cradle-Mounting Assembly: The cradle is slid between the frame rails and secured using the mounting plates. The mounting plates bolt into the original mounting holes, ensuring that no additional drilling or welding is required.
- Attaching the Tie Rod Ends: The tie rod ends are reattached to the ends of the new rack. It is important to install them at the same depth as they were on the old system to maintain proper alignment.
- Connecting the Power Steering Components (for power-assisted models): The power steering pump and fluid reservoir are installed, and the pressure and return hoses are connected to the rack unit using a hose kit (PN FR1610).
- Mounting the Steering Column: The swivel floor mount is attached to the firewall, and the steering column is aligned with the dash using an indexing groove. The column is then inserted through the floor plate and firewall.
- Routing the Steering Linkage: The universal joints and intermediate shaft are used to connect the steering column to the rack. This ensures that the movement of the steering wheel is accurately transferred to the rack.
- Connecting Electrical Components: If the vehicle has turn signals or a shift indicator light, these must be connected to the new system. The wiring should be carefully routed and secured to prevent interference with other components.
Adjustments and Final Checks
After the physical installation is complete, several adjustments and checks are necessary to ensure that the system functions correctly:
- Adjusting Tie Rod Length: The length of the tie rods should be adjusted to match the original measurements taken before the installation. This helps maintain the correct toe setting and ensures that the wheels are aligned properly.
- Securing All Connections: All bolts, nuts, and fittings should be tightened to the manufacturer’s specifications. This includes the tie rod ends, power steering hoses, and mounting hardware.
- Bleeding the System: For power-assisted models, it is essential to bleed the system to remove any air trapped in the hydraulic lines. This process involves filling the fluid reservoir, turning the steering wheel back and forth while monitoring the fluid level, and repeating until no air bubbles remain. It is important to follow the manufacturer’s bleeding procedure carefully and avoid skipping any steps.
Post-Installation Considerations
Once the installation is complete and the system has been bled, the vehicle should be taken to an alignment shop for a professional alignment. While the initial measurements and adjustments can bring the system close to the correct settings, a professional alignment ensures that the system is optimized for performance and safety.
Users are also advised to test the steering system before driving the vehicle. This involves turning the steering wheel back and forth to ensure smooth movement and checking for any unusual noises or resistance. If any issues are detected, the system should be inspected and adjusted as needed.
User Reports and Installation Challenges
Several users have reported on their experiences with the Flaming River rack-and-pinion installation, highlighting both the benefits and the challenges. One user noted that the installation process was relatively straightforward, with the mounting cradle and components fitting well into the vehicle's structure. However, they also encountered a few issues that required additional parts or modifications.
For example, some users reported clearance issues with the valve housing hitting the rack mount, which may require cutting or the use of a spacer. Flaming River offers a 1.81-inch spacer (Part #100432) for such cases, which can be used to adjust the fit and avoid interference. Users are advised to consult with Flaming River or a qualified technician if they encounter any unexpected clearance issues during the installation.
Another user mentioned the importance of using the correct universal joint and 6AN fittings when installing the system. These components are essential for ensuring a secure and reliable connection between the steering column and the rack. Users are encouraged to verify that they have the correct parts for their specific application before beginning the installation.
Despite these challenges, the overall consensus among users is that the Flaming River rack-and-pinion system is a high-quality upgrade that significantly improves steering performance in classic vehicles. The system's adjustability, durability, and compatibility with original components make it a popular choice among both professional builders and DIY enthusiasts.
Conclusion
The installation of a Flaming River rack-and-pinion system is a complex but rewarding process that can greatly enhance the driving experience in classic American vehicles. The system’s design emphasizes compatibility with original components, ease of installation, and high-performance characteristics. Users are encouraged to follow the manufacturer’s instructions carefully, take precise measurements, and seek professional assistance if needed to ensure a successful installation.
By understanding the key components, following a structured installation process, and addressing any potential challenges, users can confidently upgrade their vehicle’s steering system with a Flaming River rack-and-pinion unit. The result is a modernized steering system that combines the benefits of contemporary technology with the heritage of classic automotive design.