Changing rack, and having trouble extending the lower steering shaft to get the joint fully seated on the pinion of the rack.....
Am I missing something? Suggestions?
In past experience other cars, I would expect the shaft to extend/retract with relative ease??
2003 S Type R 4.2L SC

 

Your in Canada. Any chance it's rusted up from the road salt?
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Good chance, but it doesn't look bad up there - asking to see what "normal" should be like.
And yes LOTS of rust in the rockers!

 

I had that union apart on my 06 str last year and i had to use force to separate and even with clean up as best i could i still had to tap it strongly to reattach. It is in an akward spot that does not help. I was able to get it started then use the now free hand to hold it in a good position. Hope this helps some. Oh yeah. Make sure the splines are exactly aligned using the keeper bolt slot as reference. I was one spline off for a bit and had your same troubles

 

have oriented correctly and started now, but definitely needs to go on further - I think such that the pinch bolt passes through the cut in the pinion.

 

Is the pinch bolt removed?