This is a great writeup! Very useful when diving into the steering boxes, just for making sure you keep everything straight
One thing I will make a note on, I do not believe that bearing belongs on the end of the worm shaft but fell into that position behind the nut when you twisted things too far and had a few bearings fall out. When I disassembled the one I just rebuilt it had a full 24 ball bearings within the worm drive, 12 silver and 12 black. At one point when I was reassembling I had a ball bearing fall within the housing and thought I lost it, it ended up nestled into the end of the worm shaft just like yours, but mine was silver. Considering the ball bearings follow a continuous loop, you need an equal amount of silver and black ball bearings to keep it alternating throughout. Somewhere within your worm drive loop you're missing a black ball bearing and have two silver bearings stacked together
Winner winner chicken dinner! I pulled another box apart last night being extra careful not sping the worm gear out. I pulled the cap off the end of the piston assembly and sure enough, there was no ball at the end. Looks like Ill be pulling my box back apart (good thing its not installed yet). Ive edited the post accordingly. Good looking out!
[URL="http://www.jeepforum.com/forum/f197/tjs-01-wj-build-thread-1023461/"]4.5" Claytons, 33's, 231hd, locked, and more. Click here for details[/URL]
I apologize for commenting on a nearly 2 year old write up, but thought I should mention in Step 10, you say to measure 3/8" but the tape measure shows 3/4". I'm sure it was just a typo, but thought maybe it should be corrected so as new folks find the write-up (like I did) there won't be any confusion. Not everyone is adept at reading a tape measure these days and may go simply by the text without comparing it to the pictures
Nice article though, I will be referencing it to reseal my gear box!