Steering gear box rebuild (2 Viewers)

[80serie]

But the good thing is to learn from it. I know more than I knew last week.

Job is done and the rig is on the road again. I’d like to thanks everyone for their input in this thread. Following the steps made the job way easier.

 

[Malleus]

Outstanding!

 

[Ro Land]

REASSEMBLY

Step 7: Reassembling the worm gear valve body assembly

Press the input shaft oil seal and bearing back in. Make sure they seat properly at the bottom of the valve body housing. A large socket (~24mm), wooden dowel, or brass drift are all equally useful for this.

Put the input shaft back in the valve body housing. Use plenty of ATF to ensure everything slides in properly, and be careful of the Teflon ring if you replaced it. Then put the needle bearing and preload nut back in place.

Tighten the preload nut until the match marks line up. I tried increasing the preload but the really isn’t much room to play here and I ended up going back to “stock”

Install the lock nut and align it with the other match marks.

Now comes the tricky part, getting all the ball bearing back in the power piston. Put the worm gear shaft back inside the power piston. You should be able to get most of the ball bearings back inside the two holes by turning the input shaft back and forth. Make sure you keep the piston close to the valve head so the balls don’t fall off either end of the worm gear.

Once most of the balls are in the housing, grab the two halves of the metal tube and some sticky moly grease. Line the inside of the tube halves with grease and stick the balls inside the tube.

Put the other half of the tube on top of the first

Push the assembled tube back into the piston until you can get the metal clamp back in place. Install the two screws.


Step 8: Reinstalling the worm gear valve body assembly

Now that the worm gear valve body is back together, reinstall it into the gearbox housing. Use plenty of ATF to ensure nothing binds, and be especially careful of the Teflon ring. Make sure it isn’t caught on the edge inside the gearbox.

Install the four 14mm bolts and tighten them down to pull the valve body into the gearbox

Now reinstall the power piston plunger and guide. More ATF to lube the O-ring here too.

Step 9: Installing the sector shaft

Install the new O-ring, Teflon ring, metal ring, snap ring, and oil seal. Pay careful attention to the orientation of the oil seal.

Centre the power piston in the gearbox housing

The FSM recommends putting some moly grease on the teeth prior to installation. Install the sector shaft, making sure the teeth are centered on the power piston.

Put a new O-ring on the side cover and line it up on the adjusting screw.

Use the adjusting screw to pull the side cover down. Note the direction of the threads (lefty loosey in this case)

Install the four side cover bolts and tighten them.

Now the box is 99% back together, and you need to set the preload. It is possible to use a special SST socket on the input shaft to attach a dial torque wrench, but most of us don’t have access to either of those. I found that the difference between good and too tight was easy to differentiate while turning the input shaft back and forth from lock to lock. Adjust the screw 1/8th of a turn at a time until you get to too tight, then back it off a bit. Install the new seal washer and the adjusting screw lock nut. Be sure that the adjusting screw doesn’t move as you tighten the nut.

That’s it!


A few power steering related links:

Pump
Power Steering R&D - https://forum.ih8mud.com/80-series-tech/409610-power-steering-r-d.html
Toyota OEM PS Pump PIS and GPM Ratings & Hydraulic Winch - https://forum.ih8mud.com/80-series-tech/367350-toyota-oem-ps-pump-pis-gpm-ratings-hydraulic-winch.html
Power Steering Pump and Hose Replacement - FAQ - https://forum.ih8mud.com/80-series-tech/201920-power-steering-pump-hose-replacement-faq.html

Gearbox
Power Steering Gear Box 105 Series Sector Shaft/Pitman Arm Upgrade - https://forum.ih8mud.com/80-series-tech/336799-next-list-rebuild-ps-gear-box-new-sector-shaft-pitman-arm.html
FJ80 Power Steering Pump & Gearbox Rebuild - https://forum.ih8mud.com/80-series-tech/98211-fj80-power-steering-pump-gearbox-rebuild.html
Cracked Frame - https://forum.ih8mud.com/80-series-tech/273182-cracked-frame.html
Tightened steering nut - big benefit!! - https://forum.ih8mud.com/80-series-tech/330999-tightened-steering-nut-big-benefit.html

Fluid cooler
Power steering cooler upgrade - https://forum.ih8mud.com/80-series-tech/20738-power-steering-cooler-upgrade.html
Power steering cooler Install - https://forum.ih8mud.com/80-series-tech/343463-power-steering-cooler-install.html
Heat Sink power steering cooler install - https://forum.ih8mud.com/80-series-tech/280386-heat-sink-power-steering-cooler-install.html

Me and my Behemoth are absolutely forever thankful for your writeup!

Absolutely Grand!