Well I decided since I was going to be alone on Thanksgiving that I'd spend some quality time with the Zebra. I fired the truck up and heard a whine, checked the power steering, it was low so I topped it off. As I'm driving i notice the sound getting worse, I kept going as my shop was less thena mile away and it was all uphill (dang WV ) anyway, when I get there I get out to look and almost fell over. It was raingin under my truck!! Seems like the Power steering box took its life on this thankful day.....

Of course its in the worst possible time (xmas shopping season), becasue I wanted a redhead box, but I won't have ttime to wait now msot likely. I'm gonna go ahead and looka t repalcing the hoses and prolly the pump while I'm at it.

 

As usual the truck is fighting me every step of the way. I have everything disconnected, just have to drop the gearbox out. Its stuck on the steering shaft. I plan on putting new lines on as well if they have them in stock tomorrow.

 

You sure you're removing it correctly? If your slipshaft isn't stuck and you're sure you unbolted it (I've had many moments like that), you have to pry upwards between the shaft and the box. I usually use a wedge of some kind and hammer, it's a lot easier than using a prybar. My pickle fork pitman arm pulley works and I think I usually just use that. It needs a tapping or hammering instead of a steady pulling to get off.

Mine had never been removed and I didn't have any issue, I don't see how one could get stuck. Then again, my Bronco is backwards, when someone tells me it's going to be hard getting off, it usually comes off easy and when they tell me it should come off easy, it's usually a pain..

and man, my Redhead is nice.. don't spend too much on a replacement because you'll probably still eventually go Redhead anyways. With my Redhead + Saginaw, I have one finger steering like a Cadillac but steering that's probably tighter than your Mustang.

 

Thanks ErrorS, I was able to get it after stabbing the coupler with a screwdriver (old crappy one) to pop the shaft loose.

This is what I started the morning with:
http://www.flickr.com/photos/62639173@N03/6396760195/http://www.flickr.com/photos/62639173@N03/6396760195/ by http://www.flickr.com/people/62639173@N03/, on Flickr

So I pulled the truck in and got everything ready to begin working. The book always helps to be at hand, something to munch one, a nice beverage, and some Randy Travis on the radio:

http://www.flickr.com/photos/62639173@N03/6396761325/http://www.flickr.com/photos/62639173@N03/6396761325/ by http://www.flickr.com/people/62639173@N03/, on Flickr

Another hang-up was the pitman arm. I didn't really have enough room to use a puller, it hit the front diff. So I decided to pull the box and deal with it later. The lines were so rusted I didn't even try to remove them from the box. I dropped it out all as one unit.

http://www.flickr.com/photos/62639173@N03/6396755737/http://www.flickr.com/photos/62639173@N03/6396755737/ by http://www.flickr.com/people/62639173@N03/, on Flickr

Finally got the gearbox out. Both lines were rusted solid through, plus the gear box was leaking fluid from everywhere. Sad to say I just flushed that fluid out not too long ago....

http://www.flickr.com/photos/62639173@N03/6396763075/http://www.flickr.com/photos/62639173@N03/6396763075/ by http://www.flickr.com/people/62639173@N03/, on Flickr

Look at all the gunk build-up where the box was. I cleaned all that up and will prolly go back later tonight and sand the frame area down and coat it with some CARC paint.

http://www.flickr.com/photos/62639173@N03/6396763203/http://www.flickr.com/photos/62639173@N03/6396763203/ by http://www.flickr.com/people/62639173@N03/, on Flickr

http://www.flickr.com/photos/62639173@N03/6396763611/http://www.flickr.com/photos/62639173@N03/6396763611/ by http://www.flickr.com/people/62639173@N03/, on Flickr

By the way, if anyone is ordering parts, check out Advanceautoparts.com. If you order before 2am you get 25% off and a $50 if you spend over $100. Xmas is gonna come early for the Zebra

 

I can't seem to get the pitman arm off the box. I tried a puller, a slide hammer, a BFH, even a torch....and a new pitman arm is like $120!!

 

Have you got the proper puller
If you do, get it on there as tight as possible the whack it with a hammer while its still on the truck

I SEE YOUR PULLER NOW, you wont get it off with that, you need a pitman arm puller

 

I already got the box out with the arm still on. I have it sitting in a vise, i plan to get/rent the pitman arm puller tomorrow hopefully. Yeah that little puller was the only thing that kinda fit and it wasn't even budging.

 

Brett, thats right, you wont get it off with that, with the proper puller it will pop right off

 

Edge, if you used a torch directly on the pitman arm, you should replace it, or have it re-tempered once you take it out. Sad to say, won't be able to pull the pitman arm out unless the box is attached to the frame, check this write up of mine: https://www.ford-trucks.com/forums/1...x-rebuild.html

 

I have the box sitting in a large bench vise so hopefully that will act the same as being on the frame. Thanks for the tip on tempering it. I plan to relaxed it eventually with rest of the steering linkage. This just came out of the blue.

 

Get the conical pitman-arm puller (i think OTC tools sells one of those on amazon), it works great (i was told, check my link to see which one i used), and you'll probably need to use a breaker bar, the torque used tightening that nut in the sector shaft was enormous, i hope that vise hold the box fine.

 

Got the pitman arm off. I got all my parts lined up ready ti be put on. My new power steering pressure line has an extra fitting that is for the pressure sensor on newer trucks. Tho im wondering if it'd be usable as a T for possible hydroboost swap in the future?

 

Just plug the hole for now & you will be fine, glad to hear its appart, I guess you know there is a master spline there eh

 

Picture Time!

Here are the new parts I picked up this morning. All together it only cost me about $140 not including the core. pretty good deal I felt, plus I have a $50 gift cert I can use after Dec 7 that I got when I ordered the stuff.

http://www.flickr.com/photos/62639173@N03/6401094869/http://www.flickr.com/photos/62639173@N03/6401094869/ by http://www.flickr.com/people/62639173@N03/, on Flickr

Here is a picture of the fitting on the pressure line:

http://www.flickr.com/photos/62639173@N03/6401097141/http://www.flickr.com/photos/62639173@N03/6401097141/ by http://www.flickr.com/people/62639173@N03/, on Flickr

Not sure if its possible to run a line off of that for a hydroboost, but it would be a nice option maybe down the road.

Here's a picture of the new cooler line and gear box installed on the truck.

http://www.flickr.com/photos/62639173@N03/6401139917/http://www.flickr.com/photos/62639173@N03/6401139917/ by http://www.flickr.com/people/62639173@N03/, on Flickr

And finally a top view with new lines on.

http://www.flickr.com/photos/62639173@N03/6401098593/http://www.flickr.com/photos/62639173@N03/6401098593/ by http://www.flickr.com/people/62639173@N03/, on Flickr

I still have a faint whine even after bleeding the air out, but that's prolly because the pump went through alot of air when the gear box blew. I plan on replacing the pump next month here when I can use my coupon code! Im still also debating about doing the Saginaw upgrade if I can find the right pump.

 

Well done Brett, good job, dont forget to check for leaks, G