Durango Steering Gear in a Late Model TJ (03-06) - JeepForum.com
Reply
 
LinkBack Thread Tools
post #1 of 59 Old 07-14-2009, 11:50 AM Thread Starter
pachary
Registered User
2005 LJ Wrangler 
 
Join Date: Oct 2007
Location: Adairsville, GA
Posts: 521
Durango Steering Gear in a Late Model TJ (03-06)

After reading a few posts from MrBlaine, I decided to jump into the Durango box for my 05 LJ.

1. Remove stock box.

2. Remove steering shaft, drill plastic pin from both sides, reinstall collapsed shaft.

3. Use 1" hole saw to cut front box mount sleeve out of frame.

4. Bolt durango box using 2 back bolts and determine if sleeve will fit or if frame needs to be clearanced. I needed to grind about 1/8" from the front lower corner of hole.

5. Bolt the box back in with 3 stock bolts, tack weld the sleeve. Remove box and weld up sleeve.

6. Use a stock 97-02 TJ pressure hose, reinstall box (shaft, 3 bolts, hoses).

7. Install Pitman arm (I used a stock flat 80s Waggy arm for my D44)

8. Bleed system


My biggest problems were getting my stock return line to route in there. I will probably go with a universal clamp in return soon.

The other challenge was getting the boxex in and out by myself. They are a bit heavy and it would help to have an extra set of hands to hold it while getting bolts started.

Whole thing took about 3 hours this morning, again by myself.

Now I will be ready for high volume pump and hydro assist this winter! You actually can't even tell anything was done with the skid in place.

Paul



To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.


2005 TJ Unlimited/I6-M6/Rubi 4:1 Tcase/4.5RESF/1.25JKS BL-1BMML/37"SSRs/WarnM8000/Besttop TireCarrier/Waggy D44/ FR-RR DetroitD44/Cobra Remote CB/custom F&R Bumpers/JeeperMan Skids/York OBA/Rokmen TummyTuck/TNT 3" Fenders and Rear Corners/AA SYE- Carolina Drivelines CV Shaft
pachary is offline  
Sponsored Links
Advertisement
 
post #2 of 59 Old 07-14-2009, 12:09 PM
Jebussaves0
Registered User
 
Jebussaves0's Avatar
2002 TJ Wrangler 
 
Join Date: Apr 2008
Location: Abilene, TX
Posts: 411
Any pictures?

2002 Jeep Wrangler Sahara | 4.0L 5spd D44/D30 3.73s | Hurst Shifter |
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
| Hummer-Style CAI | 1" Rusty's BL/MML | AA TC Shifter Bracket | 2" BB | JKS Quicker Discos | 33x10.50R15 BFG KM2s | Alpine CDA-9886 HU | OTRATTW Switch Panel | G.P.F. Rear Bumper | Metalcloak Overline Fenders

M416 Trailer | In Progress
Jebussaves0 is offline  
post #3 of 59 Old 07-14-2009, 01:29 PM Thread Starter
pachary
Registered User
2005 LJ Wrangler 
 
Join Date: Oct 2007
Location: Adairsville, GA
Posts: 521
Um, no. And on your jeep it is a direct bolt in.

There really isn't much to see.


To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.


2005 TJ Unlimited/I6-M6/Rubi 4:1 Tcase/4.5RESF/1.25JKS BL-1BMML/37"SSRs/WarnM8000/Besttop TireCarrier/Waggy D44/ FR-RR DetroitD44/Cobra Remote CB/custom F&R Bumpers/JeeperMan Skids/York OBA/Rokmen TummyTuck/TNT 3" Fenders and Rear Corners/AA SYE- Carolina Drivelines CV Shaft
pachary is offline  
 
post #4 of 59 Old 07-14-2009, 01:32 PM
mrblaine
Wizard of Brakes
 
mrblaine's Avatar
1999 TJ Wrangler 
 
Join Date: Dec 2004
Location: Quail Valley
Posts: 33,106
Quote:
Originally Posted by pachary View Post
After reading a few posts from MrBlaine, I decided to jump into the Durango box for my 05 LJ.

1. Remove stock box.

2. Remove steering shaft, drill plastic pin from both sides, reinstall collapsed shaft.

3. Use 1" hole saw to cut front box mount sleeve out of frame.

4. Bolt durango box using 2 back bolts and determine if sleeve will fit or if frame needs to be clearanced. I needed to grind about 1/8" from the front lower corner of hole.

5. Bolt the box back in with 3 stock bolts, tack weld the sleeve. Remove box and weld up sleeve.

6. Use a stock 97-02 TJ pressure hose, reinstall box (shaft, 3 bolts, hoses).

7. Install Pitman arm (I used a stock flat 80s Waggy arm for my D44)

8. Bleed system


My biggest problems were getting my stock return line to route in there. I will probably go with a universal clamp in return soon.

The other challenge was getting the boxex in and out by myself. They are a bit heavy and it would help to have an extra set of hands to hold it while getting bolts started.

Whole thing took about 3 hours this morning, again by myself.

Now I will be ready for high volume pump and hydro assist this winter! You actually can't even tell anything was done with the skid in place.

Paul
Good job. It's just not that hard to do, is it?

I am Savvy
blackmagicbrakes.com
Knowledge does not equal understanding.
mrblaine is offline  
post #5 of 59 Old 07-14-2009, 01:51 PM
Jebussaves0
Registered User
 
Jebussaves0's Avatar
2002 TJ Wrangler 
 
Join Date: Apr 2008
Location: Abilene, TX
Posts: 411
Quote:
Originally Posted by pachary View Post
Um, no. And on your jeep it is a direct bolt in.

There really isn't much to see.
Um, I realize that It was really for other people's benefit

2002 Jeep Wrangler Sahara | 4.0L 5spd D44/D30 3.73s | Hurst Shifter |
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
| Hummer-Style CAI | 1" Rusty's BL/MML | AA TC Shifter Bracket | 2" BB | JKS Quicker Discos | 33x10.50R15 BFG KM2s | Alpine CDA-9886 HU | OTRATTW Switch Panel | G.P.F. Rear Bumper | Metalcloak Overline Fenders

M416 Trailer | In Progress
Jebussaves0 is offline  
post #6 of 59 Old 07-14-2009, 02:00 PM
uvalax236
Registered User
2006 TJ Wrangler 
 
Join Date: Jan 2005
Location: Richmond, Virginia
Posts: 247
Quote:
Originally Posted by Jebussaves0 View Post
Um, I realize that It was really for other people's benefit
x2!!! I want to do this on my 06. Pics of the hack-and-weld job?

06 Solar Yellow AT
uvalax236 is offline  
post #7 of 59 Old 07-14-2009, 03:04 PM Thread Starter
pachary
Registered User
2005 LJ Wrangler 
 
Join Date: Oct 2007
Location: Adairsville, GA
Posts: 521
OK, when I take it apart (not promising when), I will get pics. But I promise it really is as easy as it sounds. As long as you can drill and weld, the rest is unbolting and bolting stuff back in. I didn't take the pics as I was doing it because it was that simple (and I didn't have my camera monkey handy).

Heck it is so cramped in there, it is hard to see what is what looking with your eyes and a flashlight, especially since my winch cables and hydraulic hose for OBA go by there also.


To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.


2005 TJ Unlimited/I6-M6/Rubi 4:1 Tcase/4.5RESF/1.25JKS BL-1BMML/37"SSRs/WarnM8000/Besttop TireCarrier/Waggy D44/ FR-RR DetroitD44/Cobra Remote CB/custom F&R Bumpers/JeeperMan Skids/York OBA/Rokmen TummyTuck/TNT 3" Fenders and Rear Corners/AA SYE- Carolina Drivelines CV Shaft
pachary is offline  
post #8 of 59 Old 07-14-2009, 04:03 PM Thread Starter
pachary
Registered User
2005 LJ Wrangler 
 
Join Date: Oct 2007
Location: Adairsville, GA
Posts: 521
OK here's the pics of what you can see

Side view of the 3 bolts after install. The relocated one is furthest left.




Durango box with Waggy pitman arm:



Relocated Sleeve



To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.


2005 TJ Unlimited/I6-M6/Rubi 4:1 Tcase/4.5RESF/1.25JKS BL-1BMML/37"SSRs/WarnM8000/Besttop TireCarrier/Waggy D44/ FR-RR DetroitD44/Cobra Remote CB/custom F&R Bumpers/JeeperMan Skids/York OBA/Rokmen TummyTuck/TNT 3" Fenders and Rear Corners/AA SYE- Carolina Drivelines CV Shaft
pachary is offline  
post #9 of 59 Old 08-11-2009, 05:10 PM
UnlimitedNJ
Registered User
2005 LJ Wrangler 
 
Join Date: Jun 2008
Location: NJ
Posts: 84
Good job. I did the same thing on my LJ 2 weeks ago. I used a Chevy Astro pitman arm, works great with my over the knuckle steering and stock track bar location.



Why don't you go back to your home on whore island?!
UnlimitedNJ is offline  
post #10 of 59 Old 10-31-2012, 12:55 PM
DanZ51
Registered User
 
DanZ51's Avatar
2004 TJ Wrangler 
 
Join Date: Feb 2009
Location: Wallingford, VT
Posts: 848
Quote:
Originally Posted by UnlimitedNJ View Post
Good job.
THERE'S THE MONEY SHOT, I WAS LOOKING FOR

Niicce

You didn't plate the inside of the rail too, did you?

"I will always be an American Soldier"
DanZ51 is offline  
post #11 of 59 Old 10-31-2012, 01:13 PM
mrblaine
Wizard of Brakes
 
mrblaine's Avatar
1999 TJ Wrangler 
 
Join Date: Dec 2004
Location: Quail Valley
Posts: 33,106
Quote:
Originally Posted by DanZ51 View Post
THERE'S THE MONEY SHOT, I WAS LOOKING FOR

Niicce

You didn't plate the inside of the rail too, did you?
I don't plate them. I just make some oversize weld washers out of 3/16's and put them over the bolt sleeve. Mine are typically clipped on one side to butt up against the front tube.

The hole size is a healthy clearanced 7/8".

I am Savvy
blackmagicbrakes.com
Knowledge does not equal understanding.
mrblaine is offline  
post #12 of 59 Old 07-01-2013, 01:30 PM
2k2wranglerx
Registered User
2003 TJ Wrangler 
 
Join Date: Nov 2002
Location: pittsburgh
Posts: 1,456
To drag this back up. did you have to modify your steering shaft or your high pressure line?

93 yj. 355 chevy, heads, cam, intake, etc. 35's, bumpers, winch, lights, and a killer stereo.
2k2wranglerx is offline  
post #13 of 59 Old 07-01-2013, 01:36 PM
Benderff
Web Wheeler
 
Benderff's Avatar
2006 TJ Wrangler 
 
Join Date: Apr 2007
Posts: 5,208
Quote:
Originally Posted by 2k2wranglerx View Post
To drag this back up. did you have to modify your steering shaft or your high pressure line?
Looks like that is covered in the first post, lines #2, and #6.


To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.


To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

Benderff is offline  
post #14 of 59 Old 07-01-2013, 01:44 PM
2k2wranglerx
Registered User
2003 TJ Wrangler 
 
Join Date: Nov 2002
Location: pittsburgh
Posts: 1,456
Quote:
Originally Posted by Benderff View Post
Looks like that is covered in the first post, lines #2, and #6.
DOH. ya i'm a ******* lol

93 yj. 355 chevy, heads, cam, intake, etc. 35's, bumpers, winch, lights, and a killer stereo.
2k2wranglerx is offline  
post #15 of 59 Old 07-01-2013, 01:49 PM
2k2wranglerx
Registered User
2003 TJ Wrangler 
 
Join Date: Nov 2002
Location: pittsburgh
Posts: 1,456
Does this change the position of the pitman arm? ie: will the one that's fine on my 03 box be fine on the older box?

Thanks!

93 yj. 355 chevy, heads, cam, intake, etc. 35's, bumpers, winch, lights, and a killer stereo.
2k2wranglerx is offline  
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the JeepForum.com forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid e-mail address for yourself.



Email Address:
OR

Log-in











Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page



Similar Threads
Thread Thread Starter Jeep Forums Replies Last Post
durango steering. 99 durango 00 tj pitman arm slafferty TJ Wrangler Technical Forum 0 09-05-2009 02:28 PM
HP30 from late model YJ I8AHUMR YJ Wrangler Technical Forum 1 08-19-2009 07:55 PM
New Durango Steering Gear Box Leaking cvd TJ Wrangler Technical Forum 15 06-13-2008 10:42 AM
Late model Manifolds on early model Wooders TJ Wrangler Technical Forum 12 07-11-2006 07:57 AM
Late model mods Jeep Affecionado TJ Wrangler Technical Forum 6 03-28-2002 03:36 PM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome