Did you remove the bolt?  You will notice there is a notch cut out in the spline on the rack.  The bolt going through the u-joint must line up with this notch.  The bolt must be out of the u-joint for installation or it will hit the spline.  Once installed, the bolt can be re-installed.

Z

Andy Stalick <andystalick@GMAIL.COM> wrote:
So I am in the midst of replacing my power steering rack. The old one
came out with minimum problems. I flushed out the hydraulic system by
placing a bucket under the open hydraulic lines and cranking the
engine over until the fluid ran clean. I bolted the new rack into
place and got the tie rod ends in place in a reasonable approximation
of straight.

But I can't seem to get the steering rod and u-joint assembly into
place. The u-joint doesn't slip as far onto the rack's splined nub as
far as it did on the old rack, and consequently I can't get the two
plates on the other end to line up. I tried hammering it , and its
gotten tighter, but there's still not enough clearance. Now I'm not
even sure I can get it back off to try something new. Does anyone have
a tip for this last part of the job?

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