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Powersteering Gearbox Rebuild

From 1992 Ford Bronco “Big '92” — documented by Jeremy Millrood.

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1992 Ford Bronco - To make it easier to work on remove the airinlet tube from the air box, and set it aside. If you cannot remove this by yourself you better… 1992 Ford Bronco - These three bolts must be removed for the powersteering box to come off of the frame. 1992 Ford Bronco - When removing the steering shaft from the sector shaft, it helps to have to sets of hands. The bolt holding the drive shaft on needs to be… 1992 Ford Bronco - Removing the return lines was a little difficult, this probably took the most time, mine had never been off before. Soak with a sufficient… 1992 Ford Bronco - Getting ready to remove the pitman arm with a puller, you definitely want to use a puller. 1992 Ford Bronco - Pitman arm about to come off. 1992 Ford Bronco - Pitman arm finally removed. 1992 Ford Bronco - Once the pitman arm is removed, you can completely remove the box from your rig. There are 3 bolts going through the fram rail that will ne… 1992 Ford Bronco - Snap ring over the trashed seal. It helps to have a good set of ring pliers. 1992 Ford Bronco - Sector shaft removed completely from the box. There was a little scoring around the shaft from wear but nothing too bad. 1992 Ford Bronco - After sanding the sector shaft for about 15 minutes, I used a light grade sand paper to take the scoring off of the shaft. 1992 Ford Bronco - Installing the new seal. Find an appropriate sized socket so you can hammer the new seal in. You want it to seat tight, this will take a li… 1992 Ford Bronco - The new snap ring will go right on once the seal has been seated properly. Once this is done give the sector shaft a light coat of grease a… 1992 Ford Bronco - Here is my resealed box, looks almost like new. Installation is the reverse of the removal. You may have a little difficulty getting the st…