Steering Gearbox Rebuild -
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Unread 10-01-2005, 08:26 PM   #1
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Join Date: Oct 2005
Posts: 2
Steering Gearbox Rebuild

i have recently attempted to rebuild my stearing gearbox due to leakage and a whining when turning. Rebuilt it, no more leak, no more whine, but lots of play in the wheel...any suggestions? i have had it back out twice and cant figure out what the problem is...PLEASE HELP.

97 Wrangler Sahara
4.0L 5spd

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Unread 10-01-2005, 08:29 PM   #2
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2006 TJ Wrangler 
Join Date: Jul 2003
Location: Wichita, KS
Posts: 2,265
replace it with a durango 4x4 box.
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Unread 10-02-2005, 12:08 AM   #3
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2000 TJ Wrangler 
Join Date: May 2005
Location: Alpine, TX
Posts: 1,035
Originally Posted by MR.CLIFFORD
replace it with a durango 4x4 box.
or have it professionally rebuilt and upgraded here:
'84 CJ7, '96 CTD, '00 TJ
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Unread 10-02-2005, 12:45 AM   #4
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Was really looking to save the cash, moneys tight at the moment.
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Unread 10-02-2005, 01:49 AM   #5
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Posts: 110
I recently rebuilt mine. The bolt with the allen socket needs to be tightened more. First loosen the nut on top, then tightn it down w/ the allen wrench. Don't go too tight as the steering will be too hard and sensitive to turn. Hope this helps.
[color=red]97 Flame Red TJ[/color]
Rusty's 2" Lift
31x10.5 Pro Comp A/Ts
15x8 Xtreme Alloys
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Unread 10-02-2005, 07:20 AM   #6
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2004 TJ Wrangler 
Join Date: Mar 2004
Location: Fairfax, VA
Posts: 3,334
Theres a precedure for adjusting the box. Let me find it in the FSM.

CAUTION: Steering gear must be adjusted in the
proper order. If adjustments are not performed in
order, gear damage and improper steering response
may result.
NOTE: Adjusting the steering gear in the vehicle is
not recommended. Remove gear from the vehicle
and drain the fluid. Then mount gear in a vise to
perform adjustments.

NOTE: Off center torque (180 to 360 degrees from
gear center) = 0.4 to 0.8 Nm (3.5 in-lb to 7.0 in-lb)
This torque is set in the assembly plant and cant
be adjusted in the field

(1) Mount the gear carefully into a vise.
CAUTION: Do not overtighten the vise on the gear
case. This may affect the adjustment
(2) Rotate the input shaft with a crows foot socket
from stop to stop and count the number of turns.
(3) Starting at either stop, turn the input shaft
back 1/2 the total number of turns. This is the center
of the gear travel.
(4) Loosen the adjuster plug locknut.
(5) Place the torque wrench in the vertical position
on the input shaft. Rotate the wrench 50 degrees
each side of the center and record the highest rotational
torque in this range (Fig. 6). This is the Over-
Center Rotating Torque.
NOTE: The input shaft must rotate smoothly without
sticking or binding.
(6) The Over-Center Rotating Torque should be
0.53-0.93 Nm (4.5 - 8 in. lbs.) higher in addition to
the off center torque from above (Fig. 6). than the
Preload Rotating Torque.
(7) If an adjustment to the Over-Center Rotating
Torque is necessary, first loosen the adjuster lock
nut. Then turn the pitman shaft adjuster screw back
(COUNTERCLOCKWISE) increases torque,
(CLOCKWISE) reduces torque (Fig. 7).
(8) Remeasure Over-Center Rotating Torque. If
necessary turn the adjuster screw and repeat measurement
until correct Over-Center Rotating Torque
is reached (Fig. 7).
NOTE: To increase the Over-Center Rotating Torque
turn the screw COUNTERCLOCKWISE.
(9) Prevent the adjuster screw from turning while
tightening adjuster lock nut (Fig. 7). Tighten the
adjuster lock nut to 65 Nm (48 ft. lbs.).
2004 Black Rubicon w/ 5 spd

RE 3.5 SuperFlex & Front Trackbar / JKS 1.25" BL & MML / 35x12.5 MTRs on 15x8 AR-23s / Currie Anti-Rock / Jeeperman Bumpers / Rokmen Sliders / York OBA / Harbor Freight 8k Winch
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