Well hell I don't plan to ever go bigger than 35" tires, and I don't do any hardcore wheeling (washed out logging roads and trails typically), so for my setup it looks like a good used 80 box (or a rebuilt one) will be the way to go. Wish I could easily do a Saginaw pump on my 3FE, but at this point my OEM pump is working just fine with no issues so I'm not worried about replacing it. Even then I would attempt an OEM rebuild before anything else at that point.The 80 box has the same size spline on the sector shaft as the 60 box. To that end, you're only going to twist it if you have big tires and wheel the piss out of your truck. I put a 105 sector shaft in my 80 box on my '87 FJ60, but that's because I have big tires, and wheel the piss out of my truckFWIW, an 80 box with a good saginaw steering pump is enough to reliably turn 42s in the rocks.
If I had a stock-ish late 60 and a leaky PS box, as I once did, this would be my order of fixes, from most preferred, to least preferred:
1. Buy used or reman stock FJ80/FZJ80 power steering box, bolt it on, swap FJ60 pitman arm onto it. Easy.
2. Buy used or reman stock FJ60/FJ62 power steering box and swap it on. Easy.
3. Rebuild my current pump with parts from Toyota. Really not that hard. No SSTs needed.
4. Send my pump off for a rebuild and hope they do it right.
@Godwin it seems to be a crap shoot whether your rebuilt box starts leaking soon or not, regardless of who rebuilds it. Kinda crappy deal when you're paying someone to do it, but that's why I would attempt it on my own before sending a box off to be done by someone else..
