A word or two about steering boxes and the frame:
Do not attempt to turn the wheel unless the vehicle is rolling, it puts tremendous load on the frame and steering box and can actually damage the frame with stress cracks and whatnot..

my frame was cracked on both sides, where a bolt goes through the frame the hole had spider cracks around it so we welded a giant flat washer over the hole and repaired one side then on the inside where it was cracked horizontally we ran several beads back and forth to repair and reinforce it, i thought the box needed to be adjusted because the steering was kinda loose but it was just the box moving around on the frame..

I would encourage all of you to check the frame on both sides, cracks are easy to spot because there will be bright orange rust all around it..

 

Happens on the F-series too, especially with larger tires/wheels:
https://www.ford-trucks.com/forums/1...l#post16191483
jim

 

I didn't notice it until after i installed 17x8 steel wheels and 255/60r17 tires, that was enough to highlight the problem..

 

From what year van does this photo show?

 

Very interesting Gman. I'll check mine ASAP. AT 257,000miles mine might have the same issue.

I must add: as the "resident expert" on fasteners- your choice of "big flat washers" is very very important.

Some washers are hardened, some are not. Please be sure you don't have false confidence simply based on size/thickness.

Also, welding on a washer changes its metallurgy. This could be bad news.

Either way you are better off than having a cracked frame. My concern is that you regularly check the washers you installed.

Thanks for the tip!

 

1992 E150, it's a photo of my frame before the repair..

 

good advice and will do, at some point in time i will remove the steering box and reinforce the frame with some plate steel but it seems to be holding very well and made quite the improvement..

 

I'd weld a plate of 1/4" steel

 

Mine did this. 1/4" on the outside, and welded up in the inside. Unfortunately not a ton of room to plate the inside right now, but its a very light use motorcycle van. I downsized to 235 75 15's from big 32" 10 plys due to this.

edit: 1994 E-150

 

I don't know how much if any of this information might be useful to you but it is about repairing frame cracks
Research Bulletin 2000-6

 

Gman just for my own curiosity..........

-Did you buy this van new? If not how long ago did it come to you?

-Current milege?

-Any idea if the previous owner had installed and run wheels/tires larger than spec'd for that chassis?

-Any indication driving wise or visual inspection the cracks had formed before your recent wheel tire swap?

As Jim says something similar does happen with the F-Series of similar years as your van, no doubt the larger wheels and tires being partially responsible.

So far we've not seen a lot of this with the E-Series, at least not reported here on FTE. Still checking that area occasionally would be a good maintenance step, perhaps when lubricating the front suspension.

BTW hope those repairs are long lasting--I know you've put a lot of work and money in the new paint etc.