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How-to

1992 Ford Bronco Power Steering Gearbox Removal and Reseal

1992 Ford Bronco · Rebuild · Moderate

Documented by SuperMotors from Jeremy Millrood’s photos

The leaking power steering gearbox was pulled from a 1992 Ford Bronco and resealed on the bench with a new sector shaft seal and snap ring. The photos cover air tube removal through the finished resealed box, with reassembly described rather than shown.

  1. Step 1

    Remove the air inlet tube from the air box and set it aside to open up room around the gearbox. Jeremy Millrood notes that anyone who cannot get this tube off unaided should stop and take the truck to a qualified mechanic.

    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)

  2. Step 2

    Locate the three bolts that hold the power steering box to the frame. These are the fasteners that must come out before the box can leave the frame rail.

    These three bolts must be removed for the powersteering box to come off of the frame. (1992 Ford Bronco)

  3. Step 3

    Separate the steering shaft from the sector shaft, loosening the bolt that holds the shaft on as far as it will go, then pulling the shaft off. The photo of the return lines in the next step shows the steering shaft still attached, so the album does not settle whether this step or the return lines came first. Jeremy Millrood recommends a second set of hands for this, and says it took quite a bit of pulling.

    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)

  4. Step 4

    Disconnect the return lines, soaking them with PB Blaster and letting the penetrant sit before trying again. The photo of this stage shows the steering shaft still attached to the sector shaft, so the album does not confirm whether the lines or the shaft came off first. Jeremy Millrood reports this took the most time of any part of the job, since the lines on his truck had never been off before.

    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)

  5. Step 5

    Fit a puller to the pitman arm and draw it off the sector shaft. Jeremy Millrood is emphatic that a puller is the right tool here.

    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)

  6. Step 6

    With the pitman arm off, take out the three bolts that pass through the frame rail and lower the box out of the truck. Support the box as it comes free, because it is heavy. The photo shows the box after removal, sitting in a drain pan.

    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)

  7. Step 7

    Remove the snap ring sitting over the worn seal, then pull the sector shaft completely out of the box. A good set of ring pliers makes the snap ring easier to handle, and Jeremy Millrood found only light scoring around the shaft from wear.

    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)

  8. Step 8

    Sand the scoring off the sector shaft with light grade sandpaper. Jeremy Millrood spent about 15 minutes on this.

    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)

  9. Step 9

    Drive the new seal in using an appropriately sized socket and a hammer. Work patiently until the seal is seated tight.

    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)

  10. Step 10

    Fit the new snap ring once the seal is fully seated, then give the sector shaft a light coat of grease and reassemble the box.

    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)

  11. Step 11

    The photos end with the resealed box on the bench. Jeremy Millrood describes installation as the reverse of removal: the steering shaft slides onto the sector shaft only when lined up exactly right, the pitman arm takes some work to seat, the frame bolts need retightening after some driving, and the pump may be noisy while air works out of the system, so the power steering fluid level should be checked.

    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… (1992 Ford Bronco)

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