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I have a 05 PSD FX4 6.0 with a 4.5 pro comp lift and my steering has always felt heavy. I previously had a F150 FX4 and though that the steering going from a light truck to a heavy duty was just that way, heavy. Well as I was backing up and turning a hard left to hook up my 5th wheel, i felt a "pop" and my power steering pump statred to scream. I thought i blew a line but could not locate a leak in the line, the fluid was pouring out from the bow itself. got it towed to a repair shop and they told me the box was cracked. The repairman asked if this is a common problem with the fords because the dealer had the steering box in stock which is not really a common part to stock. So my question is that is this a common problem with the super duty 4x4's?
some steering issues pop up here and there, also there are alot of need for steering related parts threads, but not outrite steering box replacement posts...
I did a steering box on the company E250 today. It was leaking but not such failure as yours. I wouldn't say the dealer having it in stock is so rare and is related to common failure. I do alot of work with Advance auto and Bagnell. They carry many of these parts for most models on the road, if they don't have it, the dealer usually does, or can get it that day.
The F250/350 is commonly considered a commercial vehicle. A good dealer should have everything to keep their commercial accounts on the road as quickly as possible. The dealer's same day warehouse may not carry them, so they decided to keep one or two on hand. If they had dozens of them sitting around, then I would suspect an issue. Usually a gear box will blow a seal or get a flat spot, they are a wear item. The cracking is probably a metal failure or something very hard hit it, the pressure in the pump should blow a rubber seal long before cracking a cast steel/iron case.
My 06 F250 when I have it had a steering box replaced. Within a couple of hundred miles. Sounding like a dry bushing in the steering wheel and that is what it was.
When I was talking with the tech he had indicated that Ford went thru a period where there were alot of this issue and thought they had solved it. So that may be why there are some in stock still.