Well the time has come I need to replace the silly thing.
My choices are.
Ford
Cardone
Red Head
Blue-Top
Or ???

One big issue will be the core I know it must have
snapped some teeth on the gears and Ford is the only
one I know of that will take a core and not ding me on it.

Lets hear the good The Bad And The Ugly of the ones I get to picj from

 

Installed one in the kids truck 2.5 years ago. No issues yet, I think it's got around 25k miles on it now
Wasn't a horrible job, just a bit time consuming

 

I've got a NAPA gear, but I just learned it manufactured by Cardone. Same one as in the video below. This replaced my Red Head 3 or 4 years ago and it's been a good purchase.
You can buy it new (more expensive) or remanufactured at Napa. Good warranty too.

 

Did some more reading after posting this and it looks like
Red Head and Blue-Top are out do to core issues.

So I will find out if I take the core into NAPA and they say
no problem then I may do that. I know Ford won't be a
problem but the shipping does tend to eat the savings.

 

 

$30~$40 is not so bad.
Bad in not like getting hit with a $250 no core charge.

Now I need to rig up a flushing tool. I found nasty fluid
in the transfer case and have no clue what the PO used
and am now wondering what is in the PS system. I keep
finding things that point to the PO being really stupid.

 

Went steering gear box shopping today and that was 100% a bust.
1st off no one has any new ones in stock even in there distortion facilities they have to come from the manufacture. But they have no
issue with offering a reman house brand, I said Thank You, BUT NO Thanks.

I was at NAPA and they no longer carry A1 Cardone do to having a high failure rate. They now have some other brand that they don't
have any new of in stock and they have to be ordered. The guy was going to call me tomorrow afternoon to let me know the shipping.
Well crap if I am going to get hit with shipping I may as well go Ford. What a PITA this is turning into.

One other thing I found out from the NAPA guy is there is only 1 box for the 2005~2007 and that is all that box fits and that is why they don't have it in stock.

 

Go through Rock Auto.

 

Sean, Don't forget that the Ford boxes get new sector shafts, no one else does that. So if the teeth that are scewed in your box are part of the sector shaft you might not get dinged.

 

Ford said they won't have any issue with a box that has broken internals.
They just want it back. It's Red Head and Blue-Top that said that they ding
for broken parts. I can see why they do when it comes down to not being
able to get the parts to repair the box.

 

 

That is the big reason I was thinking NEW not reman. In any vehicle as heavy as our is that shaft takes a lot
of stress. Did you know that Red Head told me they don't do any magnetic particle inspection?

 

 

NDT on the shaft would be so easy and take very little time.
Yes it would be a CYA bit I also feel that the added cost would
not be that much and the safety factor is worth it.

 

I am probably going to stick with a Ford unit when the time comes. I think some of the premature failures may be lift kit related and not properly torquing the pittman arm nut. It was not properly done on mine and it was picked up on when I went in for an alignment (after I did the ball joints). They removed the steering box and torqued it to 400ft lbs on a bench vise. Really tightened up the steering. I really wonder how many guys doing this at home replace the pittman arm and take out a 3/4" torque wrench and get it right.

I have heard not such great things about Red Hat and Blue Top - and they are very pricey.