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Just for clarity, sending the PS box out for a "rebuild" is actually a "re-seal" if I'm not mistaken. Your PS box will not leak but the slop will still be there as none of those parts are replaced, not sure if they CAN be replaced. Correct me if I'm wrong.
Yeah - got me. But the PS gearbox really doesn't look that complicated to rebuild. I get that getting the ball bearings back in can be like herding cats, but that appears to be the toughest part (of course after you get the pitman off.) ...
I'm getting a second set of hands to help this evening, so I plan on using that help to find out what exactly is loose.
Have "resealed" a bunch of them, with use the preloads are lost, when the preloads properly reset the result is a tighter box. Most of the things in the box can be replaced, bearings, oversized balls, etc, but rarely need it. Most of the ones we do are on oversized tire, wheeling type rigs, so set the preload, rolling drag, on the high end or over stock spec, tighter than stock boxes.
... Do you use a rebuild kit from Toyota or some other vendor?
It's not all of that, just a bit fiddly. Keep track of them, 33 go in the piston, 11 in the bridge.
This is the important part, lots of things can cause it, tossing $$$/parts at the wrong stuff, replacing good parts, isn't productive.
If you were to do it over again, what would you do instead?
Never gone too tight myself, as that was what I heard would be bad back in FJ55 days. I'd take it just a bit looser and see what you have.
Half an inch actually sounds pretty good for an old truck. Set the adjuster where you feel is best and then drive it awhile.
For the noise, I'd also check belts and the pulleys, particularly the idler pulley. When those bearings get bad they can make similar noise.
Sounds to me like you need to replace the distributor o-ring, PCV valve, maybe the valve cover gasket, and do a valve adjustment when you've got the cover off. Valves could be too loose giving you the "knock" or slap noise at start up.
Just make sure that the steering can go back to center after turning. Also, that adjusting nut has an oil seal associated with it, and it can fail after messing with it, so keep an eye on that.Well, test drive: feels better but it might be too tight. I got back and thought I would loosen it a bit - there was oil coming out of the adjustment screw. Turns out the binding released once it warmed so things weren't tight. Tightened the locking nut and no more leak. Steering feels a lot better - just concerned it's too tight. There is still about .5 inch play. Could it be in the steering column linkage/yoke?
Follow these instruction and understand there will be some slop in the system.
Just make sure that the steering can go back to center after turning. Also, that adjusting nut has an oil seal associated with it, and it can fail after messing with it, so keep an eye on that.
This, it's not a rack system, so will always have play. If it drives like herding cats, check the toe. Alignment Setting Toe
My plan exactly. Driving to work this morning felt a LOT better. I still have the loose half / 1 inch play which I think is in the linkage, but it's a lot better overall. Now on to addressing the suspension, I guess. I just need to decide. Mr Overrit has me questioning my plan to go 2.5"
SNIP
Sounds good, but check that toe-in. She may practically steer herself once all cleaned up as best you can.
I think once that's done and she's happy going down the road, if you take care to replace bushings and any other expendables, lifting 2.5" should be fine. Not big on that myself, mostly cause I need to fit the garage, but if that fits your needs no reason not to if you follow up on making sure the caster is all squared away when done.