Energy-absorbing Steering Column

The non-attached flange at the bottom of the column, shown as part of the assembly in parts lists. Rubber gasket is more or less the same size and shape but is separately quoted. Other people have a rubber sleeve that fits over the end of the column outer, inside the flange. Also not quoted, perhaps part of the assembly like the flange.

The lower bush, plastic 'washer', spring, steel washer, and circlip that secure the bottom half of the shaft into the column, the sheared 'pins' having allowed the lower part of the shaft to be pushed out of the column.

The plastic sleeve over the collapsible 'mesh' part of the column.

Stubs of plastic shear 'pin' remaining in the holes of the outer/lower part of the shaft ...

... removed

Location of ignition switch securing screw (arrowed)

Screw slackened and switch removed

Circlip retaining the upper bearing in the column

Remains of the injection moulded plastic in the upper half of the shaft ...

... and the 'waisted' section it sits in.

Repaired shaft

The 'steps' in the shaft, the washer kept getting caught on the bigger one when I tried compressing the spring.

Box plug spanner neatly fits over the narrowest part of the shaft, and inside the spring and washer, so nullifying the effect of the first, large, step. The smaller step wasn't a problem.

'Keyhole' in plate cut to be slightly bigger than the circlip ...

... but still smaller than the washer it has to press against.

String wound up by a tommy-bar (from the same box plug spanner!) to pull on the plate and compress the spring ...

... the box plug spanner can then be removed ...

... and the circlip fitted!

Flange, gasket and alignment gauge attached to column before refitting. Subsequently I chose to attach the flange and gasket to the toe-board first, then push the alignment gauge (screw removed) on the end of the shaft through them.

Column aligned.

Align the tip of the gauge with the centre of the joint, then the hole in the gauge that lines up with the clamp bolt hole is the one to use.

Measurement several times and as careful as I can has shown that the each half of the gauge is a couple of mm shorter from screw to tip than the UJ is from bolt to spider centre, making about 5mm for the two. An orange pencil in the UJ bolt hole is lined up with the gauge screw ...

... but the tip is short of the centre of the spider, shown by the concentric rings. This is slightly concerning as this column shaft can't slide up and down inside the outer, the outer has to be bolted to the body brackets to give the correct distance between the cut-outs in the two shafts. In the event, I can get the clamp bolts in the UJ and the rack bolts back into the cross-member brackets, so all was well.