Well, my 2.5 year old Blue Top just started groaning, grinding, and ratcheting at full lock to the left, so I am suddenly and unwillingly in the market. Before shelling out the stupid coin for the PSC unit, I am going to mock-up a gear from an 06 and see if there are any clearance issues. If it's a no-go then I'll be ordering a PSC as soon as I am able to afford it. Now that the ported option is only an extra $50, I wonder if a steering assist would be worth it with barely bigger than stock tires (285/75R16). Maneuvering this pig in parking lots does take a lot more effort than it seems like it should.

 

I'd definitely be interested in knowing how it goes.

 

https://www.skysoffroaddesign.com/pr...31ec3722&_ss=r

This business makes tapered sleeves to repair worn pitman arms. Using a mill to bore out the old taper to just under 1”, you chill the sleeve and heat the bored pitman arm, then press it in. Then heat up the arm and TIG weld them together.

They might have them to rework the later arms that fit the later Ford box to fit the ‘99-04 tie rods.

 

I like the way you think Jack, but there is still the difference in length of the pitman arms (03 being longer) to deal with.

 

Yes, I know, but the gear ratio is also a factor in the pitman arm length, as well as the length of the arm at the knuckle. Ford played a lot with this in the early years, 99-04. Boxes, too. Just because the pitman arm has a different length does not mean it has the same leverage and degree to turn of the knuckle.

 

You doing anything to the rest of the system or just change the steering gear out? I think my dually box has problems. Feels like zero power steering but the brakes work fine, running stock 17s so basically the smallest tire they put on these.

 

Well I guess we'll find out when I install the 06 gear. Gonna be a few weeks though.

 

I have already replaced everything but the cooler, which is why I am considering getting a ported gear, because one day I just may decide to try the cylinder assist, or will a brand new gear make all the difference?

It was definitely easier to maneuver with the stock sized radials that came on the truck; and also easier with the Toyo's which I believe was due to harder rubber compound than the KO3's.

It does stand to reason that if the flow is good enough that the brakes still work well, the gear would be the weak link. I am sure Jack has something to say about that.

 

You're putting a stock 06 steering box on your 04 🤔

 

We went over this nine posts ago. It's for testing. Though I don't have high hopes.

 

Oh yeah lol