PS gearbox, rebuild or replace? 91 E350
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Mountain Pass
Joined: Aug 2019
Posts: 141
Likes: 14
PS gearbox, rebuild or replace? 91 E350
I can't remember where I read or heard but I seem to recall some scary info about rebuilding these gearboxes. Something about them exploding. What's prompting this is I just got done sorting out, what I thought, were my last few fluid leaks. Coolant dripping from the radiator, a little bit from the expansion plugs, and PS fluid from the lines. Got all that done, cleaned it up, and I still have a leak from the gearbox. I believe it's just the input shaft seal but if I'm going to remove it again I'm inclined to do it all. I've rebuilt a rack and pinion that didn't turn out well but at the same time I've rebuilt engines and transmissions that are still going strong hundreds of thousands of miles later. Is rebuilding a Ford gearbox really that big of a deal?
Cargo Master
Joined: Sep 2012
Posts: 2,112
Likes: 286
From: Eastern TN
It’s a different skill set than rebuilding an engine or transmission. A lot of precision required in setting preloads (e.g., rotational drag) vs clearance (e.g., Plastigage), and a good eye for what’s worn vs serviceable. Diffs require still different skill set.
The seal can’t be replaced without opening the box?
Finding a quality rebuild might be a bigger challenge these days :/
Sixto
07 E350 5.4 189K miles
The seal can’t be replaced without opening the box?
Finding a quality rebuild might be a bigger challenge these days :/
Sixto
07 E350 5.4 189K miles
Thread Starter
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Mountain Pass
Joined: Aug 2019
Posts: 141
Likes: 14
TPH actually has the Sunsong rebuild kit in stock so I'm going to check it out and see what happens. Worst case, Rock Auto has new and remanned available if I screw it up.
Thanks
Hotshot
Joined: Jul 2020
Posts: 10,411
Likes: 2,612
From: Near Salt Lake City
I have rebuilt hundreds of them
The older ones are pretty easy
First thing I learned is there are 27 ***** in the control valve shaft worm gear but they will work with "less"
Later on after researching this and replacing several 1000 dollar control valves
Found out thenew Frd control valves come with 29 and they want you to put in as many as they will hold
If you put in too many they try to bind up
They have revised input shaft seals for that leak
Some need a new sector shaft to fix that seal leak
Good luck, easy job to cookbook for a beginner
The older ones are pretty easy
First thing I learned is there are 27 ***** in the control valve shaft worm gear but they will work with "less"
Later on after researching this and replacing several 1000 dollar control valves
Found out thenew Frd control valves come with 29 and they want you to put in as many as they will hold
If you put in too many they try to bind up
They have revised input shaft seals for that leak
Some need a new sector shaft to fix that seal leak
Good luck, easy job to cookbook for a beginner
Hotshot
Joined: Jul 2020
Posts: 10,411
Likes: 2,612
From: Near Salt Lake City
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Hotshot
Joined: Jul 2020
Posts: 10,411
Likes: 2,612
From: Near Salt Lake City
You do not need a vise or any holding fixture
I just clean them up in the solvent tank and rebuild them on the bench
I just clean them up in the solvent tank and rebuild them on the bench
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Hotshot
Joined: Jul 2020
Posts: 10,411
Likes: 2,612
From: Near Salt Lake City
Not easy, that is a picture of a book I have with my crappy phone
At the library you can print out the pages and take them home for free
I go twice a week most weeks looking up oddball Mercedes or Audi stuff
If I were to print out the pages at the library for you, I'd still have to take a photo of them to put on this site
I have tried to email myself the pages from the librarys computer system and cannot seem to be able to do that yet
At the library you can print out the pages and take them home for free
I go twice a week most weeks looking up oddball Mercedes or Audi stuff
If I were to print out the pages at the library for you, I'd still have to take a photo of them to put on this site
I have tried to email myself the pages from the librarys computer system and cannot seem to be able to do that yet
Thread Starter
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Mountain Pass
Joined: Aug 2019
Posts: 141
Likes: 14
Ended up replacing just the input shaft seal because I could not remove the pitman arm. Got the Balkamp puller from Napa and with my 30" breaker bar it wouldn't budge. The seal did the trick though. No more leaks!
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