Clattery when cold
Join Date: Feb 2012
Location: United Kingdom
County: Greater London
You'll find it's easier just to junk the spindles and insert bolts. I am pretty sure I just ran an M6 tap through the spindle holes in the end, though I had thought M8 would be necessary. Bolts mean you can discard the rack that operates the spindle pinions, and doing so eliminates a possible site of future trouble. The (plastic) rack may be quite worn and capable of jamming otherwise. Also the upper tiny plastic bearings will be knackered, and the larger lower ones worn enough to leak air from the manifold. Loctited bolts will seal fine.
One tip: it's much easier to remove and replace the manifold split into plastic and metal parts. Doing so allows the studs to be removed or inserted far more easily, which is necessary to get the thing off (or on).
It's really quite simple stuff, and massively worth doing in conjunction with EGR blank and map out. Forget theoretical loss of low end torque. Once there's no exhaust gas to mix the swirl flaps serve no useful purpose, and the motor pulls well and smoothly from tickover up. It will work OK without the remap aside from putting the MCSF on with a P0401 fault, but an EGR-delete remap from Autolusso was immediately and obviously beneficial from the moment I pulled away from their shop. Car is a pleasure to drive now, goes really well and gives 46.5 mpg (fill-to-fill calculated) mixed use.