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I've a new leak, power steering fluid is escaping (rapidly) at seal on the sector shaft..... (Shaft where pitman connects) Can this seal readily be replaced or am I looking at a bigger job (perhaps buying a few shares in Ford?? ). Anyone who has been down this road before please comment/advise.
Had same thing on my dads '84 truck a couple of weeks or so back. Seal kit was available for $13. Had a Heck of a time getting the pitman arm off, broke two pullers and bought a third before I got it. Then the only part that was usable in the kit was the seal, but that is all I really needed anyway. Next the pitman shaft wouldn't go back in. Spent several hours playing with it then gave up. Went back the next day, looked in the secter and realized the other gear was in the way. With my finger I pushed it back over into place and slid the shaft in easily. Took a few tries to get it centered because I had turned everything when the shaft wouldn't go in, but the rest of the job took only minutes. About a week later it started leaking again. Today I am going to do it again in hopes that I damaged the seal the first time messing with the shaft. Will let you know in a few days how it turns out this time. It you tackle it be sure to take note of the position of that other gear, can't remember its name offhand, and save yourself some grief.
Mine was leaking just like yours, I knew about the sector shaft seal kit, but I put in a new steering box anyway. It was worn out. The box swap was straightforward, took 2 hours. Works great, no backlash in the steering wheel.
You say that the 'pitman shaft would not go back in' do you mean that the sector shaft would not go back into the pitman arm or did you take the sector shaft out of the gear box? I ask because other posts I have read suggest removing the seal(s) by first removing the retaining clip (after breaking pitman arm pullers, this seems to be a common problem) and then flashing up and turning the steering wheel (quickly?) to blow out the seal(s).
Also, 13 bucks for seals sounds cheap, were you able to buy just the sector shaft seals? All I can find is seal kits for the whole gear box...