I thought it may be handy to have a general Power Steering Rebuild thread to collect some of the info running around the forum. Maybe this will reduce someone's searching efforts down the line.
I found a few threads in particular to be helpful:
Page 22 of @DSRTRDR's rebuild thread had some helpful pictures and tips. This was, honestly, the most helpful bit I found. Though it’s an 80-series box, it is nearly identical in terms of disassembly and rebuild.
the DSRTRDR is getting some TLC . . .
Handy reference on the number or recirculating balls.
Help needed Power Steering Box 40 series
The rebuild kit required and some discussion on the ball bearings.
Fj40 Original Power Steering Box Rebuild
Danny’s walkthrough on sending it out for re-sealing.
RESOLVED. Help? Power Steering GearBox
I went ahead and bought the kit (available in the region through the parts network we have). Part# 04445-35040 (mentioned in one of the threads above). Ran me about $65 USD (paid in AED here locally).
So now some pictures and pointers to help others who may want to tackle this in the future. I’ve put some notes in the pictures to highlight where some of the various seals go.
The end of the cross shaft, where the pitman arm attaches, will be a mess. Mine was dirty and a bit rusty. Lacquer thinner and a brash brush did most of the work. I then popped it in a vice and ran over the whole shaft with some fine sand paper to polish the whole thing up. Ideally I would have run this through a lathe similar to the work done on DSRTRDR’s, but I was able to get it nice and smooth. We’ll see if the remaining pitting gives me trouble in the future…
Here it is taken down into the primary components… cross shaft, piston/valve body assembly, and gearbox.
Here is the piston/valve body laid out in pieces with the respective seals.
And some closeups:
The @DSRTRDR link has excellent photos and write-up on the following:
I’ll add the following input:
Here are all of the old seals and rings I removed. One of my brass fittings was missing. I'm posting this because I forgot to take a pic before starting of the kit with all new parts.
I found a few threads in particular to be helpful:
Page 22 of @DSRTRDR's rebuild thread had some helpful pictures and tips. This was, honestly, the most helpful bit I found. Though it’s an 80-series box, it is nearly identical in terms of disassembly and rebuild.
the DSRTRDR is getting some TLC . . .
Handy reference on the number or recirculating balls.
Help needed Power Steering Box 40 series
The rebuild kit required and some discussion on the ball bearings.
Fj40 Original Power Steering Box Rebuild
Danny’s walkthrough on sending it out for re-sealing.
RESOLVED. Help? Power Steering GearBox
I went ahead and bought the kit (available in the region through the parts network we have). Part# 04445-35040 (mentioned in one of the threads above). Ran me about $65 USD (paid in AED here locally).
So now some pictures and pointers to help others who may want to tackle this in the future. I’ve put some notes in the pictures to highlight where some of the various seals go.
The end of the cross shaft, where the pitman arm attaches, will be a mess. Mine was dirty and a bit rusty. Lacquer thinner and a brash brush did most of the work. I then popped it in a vice and ran over the whole shaft with some fine sand paper to polish the whole thing up. Ideally I would have run this through a lathe similar to the work done on DSRTRDR’s, but I was able to get it nice and smooth. We’ll see if the remaining pitting gives me trouble in the future…
Here it is taken down into the primary components… cross shaft, piston/valve body assembly, and gearbox.
Here is the piston/valve body laid out in pieces with the respective seals.
And some closeups:
The @DSRTRDR link has excellent photos and write-up on the following:
- Replacing the 44 ball bearings into the piston
- The o-ring, Teflon seal, spacer washer, and ring clip that go in for the cross shaft
I’ll add the following input:
- This took me a long time to figure out... Once you’ve greased the balls that go in the split tube, place the piston over the end of the worm shaft until you can see the first groove in the “lower” hole of the piston. Drop a ball in and then screw the shaft in just a bit more. This will pull the ball in. Add another ball. Screw the shaft in just a bit more. Add another ball… and on until the 33 are in. As you place number 33 and screw the shaft a bit you’ll see the first one just appearing in the other hole. Now secure the recirculating tube.
- As you insert the piston back into the gearbox the new Teflon seal on the very end of the piston wants to catch as it passes through the cross shaft opening. Be ginger with it here... help it squeeze in with a small flat bladed screwdriver or even a small pick.
- It really doesn’t feel right how much you have to make the Teflon seal into a “heart” shape. Bend that sucker and once in it smooths our fairly well.
- I had 3 parts left over… two identically sized large o-rings and one machined brass bushing/fitting. There are three of these brass fittings in the pack… two are larger and one is smaller. The two larger drop inside the threaded input and output holes for the hydraulic lines.
Here are all of the old seals and rings I removed. One of my brass fittings was missing. I'm posting this because I forgot to take a pic before starting of the kit with all new parts.
