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About 4 months ago I replace the rubber bushing in my steering coupler on the 78. I used a repair kit from HELP I found at the local parts store and it seemed to go in o.k.. I was looking at it the other day and noticed that the new bushing was split in two places where it bolts together. I have ordered a new one from Corvette Central and will be putting it on this week-end so I hope to solve this problem for good. This could be a dangerous problem if others are having the same expierence with replacement bushings.
I just finished installing a replacement flexible coupling (rag joint) tonight. Its also one of those "Help" products. One thing I noticed is that its far more flexible and soft than factory. Also, it does not have the wire mesh layers inside the rubber like factory. It looks like it has a sewn-in material. After installing, it looks like the rag joint is sort of wavy. Its not perfectly round even though its aligned properly from column to steering box. I'm not impressed and plan to replace with a GM rag joint in the future.
I was the Senior Project Engineer responsible for the flexible coupling back in the early 70s. The rubber disc was a lamination of cotton cloth and neoprene rubber. The passenger car (with power steering) disc had four layers of cloth. All Corvettes (and passenger cars with manual steering) had seven layers of cloth. The more cloth, the stiffer the disc. All the different coupling discs were all manufactured by only one manufacturer in New York. Pre 1970 flexible couplings had a small copper strap that served as a horn ground. Around 1970 we introduced a molded wire screen in the face of the coupling disc that took the place of the copper horn ground strap. You can actually feel the ends of the screen if you run your finger along the edge of the coupling disc. The screen doesn't really add any strength to the disc but it does provide a ground circuit.
I have no idea who manufactures the discs for these rebuild kits. I doubt that they are anywhere as durable as the OEM parts.