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Rebuilding the Trooper Steering Box

Date: 2002, Aug 18
Author: Sam Jelinek

Add to any service

Tools needed:

  • basis hand tools
  • pitman arm puller
  • 17 mm crows foot line wrench

    Instructions:
    Remove front splash shield and unbolt the sway bar from frame only, not from the lower a-arms. Punch mark pitman arm, shaft and gear box housing, as well as marking steering shaft to gear box (this is for alignment when reinstalling gear box)

  • Remove pitman arm


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  • Remove bolt for steering shaft
  • Remove pressure line with crows foot
    leave other line attached to gear box,


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  • Remove line from reservoir
  • Unbolt gear box from frame and remove steering shaft. other items may need to be removed to get gear box out, like alt. or air pump. depending on model of truck

  • Place in a vise and remove the nut on top of the gear box
  • Remove the 4 14 mm head bolts.
  • Turn the screw in and remove the top of the gear box, see photo
    make sure you have a pan under the gear box


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  • Push the pitman shaft up and out of the gear box.
    some force will be needed, use a plastic hammer or block of wood to force shaft up
  • Remove the 4 14 mm bolts from selector shaft housing
  • Remove the selector shaft and housing, do not
    let the end of the selector shaft come a part see photo below
  • Remove old seals from the bottom of gear box.
  • Remove dust seals from selector shaft, remove snap ring
  • Remove old seal.

  • Clean all parts as needed.


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  • Reinstall seal and snap ring on selector shaft
  • Install new seal on bottom of gear box housing


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    This side of the seal will face up Be sure to replace this o-ring and make sure it does not fall out see photo


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  • Install selector shaft and pitman arm shaft


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  • This is the time to make sure all the punch marks are lined up
  • Reinstall top cover by turning the screw out, when turning down some light tapping is needed to align the top of the gear box.
  • After tightening the top,adjust screw down until it stops. Then back it off 1/4 turn and install new nut
  • Reinstall gear box Hint: Install line back on to gear box before bolting to frame add fluid as needed


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