i finally got around to changing my rack on my black 90 5spd sc. Its been leaking since i bought the car damn near 2 years ago but i've been putting it off just because i very much dislike those fittings at the rack underneath the engine mount brackets.
I really didn't have a choice though, the p/s pump seized up from no lube since i've been driving the car with no p/s thus no p/s fluid. It took out the belt too
anyway, i think i figured out why my old rack leaked, the return line fitting at the rack was stripped and wasn't engaging the rack correctly. I'm about 95% sure thats where it was leaking at. I had to source a new fitting from the yard. While I had the rack out I changed the tie rods as well.
The tie rod on my driver side was the original whilst my passenger side was aftermarket. That tie rod was so badly worn the joint was almost worn through the housing, I'm pretty sure they didn't change it because it was frozen in the spindle. I had to persuade her with the grinder
Good thing the pump seized when it did or else I would have been sitting on the side of the road upset because my tie rod snapped or maybe in an accident.
anyway... just a couple tips for those who are changing the rack anytime soon.
1> mount the return line fitting on the rack prior to install, be sure its between the two hard lines. You'll see what I mean when the time comes.
2> instead of putting the bolts in from the front like stock, put them in from the back, it makes it MUCH MUCH easier to fasten it.
3> the newer thunderbirds have a larger p/s cooler. I sourced my new return fitting from a 94 that had a LARGE p/s cooler, about 4x larger than the stock supercoupe cooler.