1972 Manual Steering Box Rebuild

[joeray]

At the very least, the pitman arm has to be disconnected. Better to have the gear removed from the truck. The worm bearing preload is adjusted first, with the mesh loosened 2-3 turns. This is done with a shim pack. After that is correct, adjust the mesh. You will need an in-lb torque wrench.

 

[Boccanegra]

It would be extremely helpful. If you can't turn the input shaft with one at all, it clearly indicates it's not within spec. You're not supposed to put all your might on the torque wrench to get the box to turn, you lightly turn it to check to see if the box is within spec. Loosen the nut/screw assembly and keep trying the wrench to get the inch pound reading. If you loosen the adjusting mechanism as far as it'll go and you still have to put too much torque on the input shaft, then clearly something is wrong. The torque wrench is the only tool that's accurately going to tell you that.

What kind of grease do rebuilders fill these boxes with? I have 2 manual boxes sent to me for comparison. Before I installed the first one, we tipped it upside/down with the filler plug removed and nothing poured out. If it was filled with 90 weight oil, per the Bronco manual's suggestion, I would think the oil would pour out. The rebuilder assured me that their boxes are all pre-filled (supposedly with grease, not 90 wt oil). Could a grease that is overly thick cause hard, sticky steering? If I need to replace the grease with gear oil, what's the best way to remove the thick grease? Any suggestions are greatly appreciated!

 

[joeray]

Rebuilding these boxes it's easier said than done, mainly because the input shaft bearing races are usually badly worn and pitted. New input shafts are not available any longer. Tom's top end rebuilt boxes are extremely expensive, mainly because they need to steal the best parts from several boxes. Been there. If you want to know what's inside the box, the best way would be to pull the top cover plate. To do that pull the four bolts, remove the nut from the adjuster screw, and then turn the adjuster screw down through the top plate as it comes off the housing. I've known some people to fill the boxes with STP, but not grease.

 

[joeray]

If the box is set up correctly, there should be some resistance turning it through center, but not at its outer turning limits.

 

[Boccanegra]

If the box is set up correctly, there should be some resistance turning it through center, but not at its outer turning limits.

Had a mechanic who is very knowledgable with older vehicles test drive my Bronco today (with the first box I got from Buyautoparts installed). He immediately said something is wrong. The new tie rod and drag link appear to be OK. So I'll put the second box that Buyautoparts sent me this coming Monday. Crazy. At this point I'm considering putting my old steering box back in and just replacing the sector shaft and worm gear seals. Then fill it up with 90-140 W gear oil. Getting frustrating.

 

[Boccanegra]

Had a mechanic who is very knowledgable with older vehicles test drive my Bronco today (with the first box I got from Buyautoparts installed). He immediately said something is wrong. The new tie rod and drag link appear to be OK. So I'll put the second box that Buyautoparts sent me this coming Monday. Crazy. At this point I'm considering putting my old steering box back in and just replacing the sector shaft and worm gear seals. Then fill it up with 90-140 W gear oil. Getting frustrating.

I don't know where this black clip goes, somewhere inside the bell coupling. I read somewhere that it's an "anti-pivot clip" (or similar). The pic shows it in the middle to the left of the boot. Apparently the bell coupling that I removed did not have it, but my column was rebuilt about 6 years ago and since he used some wrong parts, he might have just omitted the clip. Any feedback on how to install it or whether it's necessary?

Manual Steering Bell Assembly

New Manual Steering Bell Assembly for 66-77 Classic Ford Broncos. Connects the Steering Shaft to your Manual Steering Gear Box. NOTE: You must reuse

tomsoffroad.com

Manual steering boot assembly

 

[Boccanegra]

Does anyone have a suggestion?
I don't know where this black clip goes, somewhere inside the bell coupling. I read somewhere that it's an "anti-pivot clip" (or similar). The pic shows it in the middle to the left of the boot. Apparently the bell coupling that I removed did not have it, but my column was rebuilt about 6 years ago and since he used some wrong parts, he might have just omitted the clip. Any feedback on how to install it or whether it's necessary?

Manual Steering Bell Assembly - TOMS OFFROAD ​

New Manual Steering Bell Assembly for 66-77 Classic Ford Broncos. Connects the Steering Shaft to your Manual Steering Gear Box. NOTE: You must reuse

tomsoffroad.com

 

[Oldtimer]

This video may answer your question:

 

[Boccanegra]

This video may answer your question:

Thank you!!! I searched all over and couldn't find this. Mine did not have a spring at the end of the shaft, Now I see where the little clip goes - at the end of the shaft. Probably don't need the spring. I imagine the clip pushed the shaft up just enough that a spring isn't needed. I found it easier to keep the column in place and just loosen the steering shaft clamp at the lower end of the column to push the shaft up enough to get clearance to remove the bell coupling from the shaft. THANK YOU!

 

[Boccanegra]

Thank you!!! I searched all over and couldn't find this. Mine did not have a spring at the end of the shaft, Now I see where the little clip goes - at the end of the shaft. Probably don't need the spring. I imagine the clip pushed the shaft up just enough that a spring isn't needed. I found it easier to keep the column in place and just loosen the steering shaft clamp at the lower end of the column to push the shaft up enough to get clearance to remove the bell coupling from the shaft. THANK YOU!

Here's another video showin that matal clip placed sideways. Maybe this is better. He isn't using a spring.