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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 stop and go to a qualified mechanic.
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These three bolts must be removed for the powersteering box to come off of the frame.
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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 loosened as much as possible. Once is is loosened you should be able to pull it off.
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Removing the return lines was a little difficult, this probably took the most time, mine had never been off before. Soak with a sufficient amount of PB Blaster and go have a beer, come back and try again. After a few busted knuckles it should come off.
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Getting ready to remove the pitman arm with a puller, you definitely want to use a puller.
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Pitman arm about to come off.
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Pitman arm finally removed.
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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 need to be take out first. but once they are off the box will come right down. Be careful!! The box is heavy.
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Snap ring over the trashed seal. It helps to have a good set of ring pliers.
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Sector shaft removed completely from the box. There was a little scoring around the shaft from wear but nothing too bad.
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After sanding the sector shaft for about 15 minutes, I used a light grade sand paper to take the scoring off of the shaft.
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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 little effort so be patient.
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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 and button everything back up.
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Here is my resealed box, looks almost like new. Installation is the reverse of the removal. You may have a little difficulty getting the steering shaft back on the sector shaft, but once its lined up exactly right, you'll know and it will slide right on. The pitman arm gave a little trouble going back on but with a little work it finally seated. Make sure to tighten the bolts that hold the box to the frame down, and re-tighten after you have driven for a while. Your pump may make some noise as the air gets force out of the system, so keep checking the powersteeting fluid level. Enjoy your non-leaking powersteering box.
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