Power Steering Gearbox Tips & need some advice

[NocalFJ60]

I have had constant power steering issues since I got the engine back in 2 years ago. It all started with putting in a bad rebuilt box which slowly leaked from the top adjustment nut and setscrew. I would tighten the nut but it would slowly come loose and leak. I pulled that box and sent it out for a rebuilt with another 2 others old ones and got two good rebuilt ones back. One of the gearboxes came through the box during shipment back and hit the bottom of the sector shaft which messed up the threads. The first rebuilt box I installed on there about 6 months ago had a slow leak where the high pressure line goes into the gearbox and I didn't notice until driving to Moab. The high pressure line was new. I ended up driving it back from Moab with a small leak. Today I replaced the high pressure hose and it was leaking just a little bit while bleeding it. It seems tight so now it is time to pull the box again and pull the bronze? inserts that mate to the end of the hose to check them. It has to be the box at this point. I remember looking at the bronze inserts when I put in the rebuilt box and they looked good. I am going to put in the spare box once I can fix the sector shaft threads.


Some things I have learned so far...

Use a good amount of thread locker on the setscrew on a new rebuilt box after you adjust the play in the box and then lock down the nut while holding the setscrew so it doesn't turn. If you try and turn the steering lock to lock with both wheels on the ground with no power steering, then it might loosen up the nut on the setscrew.

Tighten the high pressure hose to the gearbox while watching from above and make sure the hose doesn't touch the fender while tightening it.

Questions:

The first hose was from Napa and this new one was from Carquest. Anyone replaced the high pressure hose and where did you get it? Did it work fine?

How can I repair the threads up the sector shaft? Do you have to get a thread file for a certain thread size or is there a standard one?

Anyone know what size threads are on the sector shaft? I am measuring about 21mm. Should I try a die first?

Anyone have any ideas on what to check or try next to stop the leaks on the high pressure hose?

Can you still buy the bronze inserts from Toyota?

 

[weak-link]

the right way would be a die but I would try a thread file first=cheaper

 

[2mbb]

The seat appears to be available.

 

[rchalmers3]

Questions:

The first hose was from Napa and this new one was from Carquest. Anyone replaced the high pressure hose and where did you get it? Did it work fine? Have not replaced one yet, but if you got a new hose with a bad flare, you will need to replace the hose to eliminate the leak. Are you using a tubing wrench to tighten it down to the box?
How can I repair the threads up the sector shaft? Do you have to get a thread file for a certain thread size or is there a standard one? Yes, you need the specific thread file.
Anyone know what size threads are on the sector shaft? I am measuring about 21mm. Should I try a die first? Tap and die sets usually come with a thread guage if you need the thread count. I would not recommend using a die when the starting threads are buggered. Plus a die will be expensive.

Anyone have any ideas on what to check or try next to stop the leaks on the high pressure hose? Yes. Carefully inspect the flare on the hose end for splits in the metal. Check that you have compatible parts(aircraft hose flare to non-aircraft flare for example) Look to see if there's any reason the fitting is not fully seating. You should see the crushed and seated markings on the flare. If you see abnormalities, check the box mating surfaces and threads. Finally, use a tubing wrench and make sure you can exert sufficient pressure to clamp the flare permenantly!

Can you still buy the bronze inserts from Toyota? 2mbb has you covered on that one.

Good luck and let us know what you find.

Rick

 

[NocalFJ60]

Good luck and let us know what you find.

Rick

What is a tubing wrench? I am using a open ended wrench about 8" long. Should I get a longer wrench and really crank on it? I just looked at the manual and it says 38 ft/lbs. How tight do you get them? I inspected both hoses and the flare looks good and is not split. I think the insert piece is not seating with the flare on the hose good now or the threaded piece on the hose bottoms out before it seats with the flare. But after trying another hose I think it is seating with the flare cause the metal tube on the end of the hose feels tight and I can't turn it.

Where would I get a thread file? Might just try and take it to the machine shop and see if they can fix it. I don't want to mess up this box.

 

[hank14]

I'm running a NAPA high pressure PS hose on a freshly rebuilt box. 6 months and 4,000 miles on the hose- no leaks. The rebuilt box is leaking from the original spot again, however- the steering shaft input.