Getting to the steering
box once the engine is removed is easy. Don't forget that my Niva is RH
drive. The first thing I did once I had the steering box removed was make
up a very simple jig using some offcuts of timber. The purpose of this
jig was to be able to locate all the holes in the pitman
arm and steering box mounting holes relative to each other. I could then
place the Toyota box on the jig and see how far out everything was. In
order to be able to fit the Niva pitman arm on the Toyota box for this
procedure I had to file the splines out of the pitman arm so it could slide
over the Toyota shaft. By sliding the pitman arm as far up the shaft as
the original Toyota arm had been I determined that it would end up being
just under 10mm to low. This being due to the fact that the Toyota box
extends that much lower below its mounting holes. For now I have called
that "close enough". What sort of effect this will have on the steering
or wheel alignment I am not sure about at this stage. If there are any
negative side effects due to the centre steering rod being on a slight
angle I will probably correct the problem by dropping the idler arm a corresponding
amount. Lifting the steering box is not possible as the bolts pass through
tubes in the chassis to stop the chassis from being squased. Bending the
pitman arm is not allowed for certification reasons. The next problem to
solve was getting the right splines into the Niva pitman arm. My idea was
to use the splines out of the Toyota pitman arm by machining and turning
the arm until we were left with a bush with the splines in the middle.
The Niva arm could then be bored out to accept this bush and the two welded
together. However the engineer I went to see to get this done felt that
there wasn't enough metal in the Niva arm to do this safely. His idea was
to build up the inside of the hole by metal spraying and then spark eroding
the right splines back into the Niva pitman arm. This is being done at
the moment. I will post a picture of what it looks like as soon as I get
it back.
The next area to concentrate
on was to actually get the steering box to fit into the car. As I mentioned
before the brake booster gets in the way of things so that was the first
thing to be removed. On the first trial fit it became obvious that the
hole were the Niva steering shaft originally passed through the firewall
was no where near big enough to accomodate the Toyota box as part of the
casting ends up being inside the passenger compartment. Here are two pictures,
the first one is a side view of the steering box temporarily fitted to
the car while the second picture shows how tight everthing fits once
the engine and startermotor are in place.