I have a 2003 F-150 XLT 7700 series 4x4 with a 5.4L. The other day the seal let go on the power steering box.

i noticed that the pitman arm is strange and it has the ball joint inside of it instead of the normal way with the joint in the center link.

I got the castle nut and cotter pin out, but I cannot seperate the pitman arm from the center link. I put a pitman arm puller on it and I almost broke it with the amount of force I put on it. Since the center link is at an angle to the ground the puller wants to move. I hit the arm with a hammer nothing seems to break it free. I wanted to try and re use the pitman arm to save money but at this point I don't care if I have to torch it off!! It seems impossible because the pitman arm is rigid with the steering box and the center link seems not to have any give. I cant just remove the arm from the steering box because Ford thought it would be great to put the frame x-member directly below the box.

Are there any tricks to remove the box? I must say I'm pretty pissed right now, and just looking for some advise.

Also there is a plastic cone that covers the intermediate shaft pinch bolt, which seems to be made in two pieces, which I can't seem to figure out.

In my 88 F-150 I was able to change my steering box in less than an hour. Sometimes I miss owning a 2wd trucks, there much easier to work on, I also miss the twin I-beam suspension, to me seemed much stronger and durable in my opinion.

Thanks for any help in advance.

 

Were you trying to separate the pitman arm from the drag link with the wheels on the ground? if so it wouldnt allow for movement of the rest of the steering linkage. Did you try heating the area where the ballstud goes through with a torch and then try the puller? Im not sure how it is setup on the 7700 version but on the 03 f150 6750 gvw 4x4 the ballstud is on the pitman arm not the drag link. I see this post is a few months old, but i would be interested to know if or how you got it apart.