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Was driving down a bumpy road, lost all power steering with zero indicator of failing other than sudden loss of power assist. Checked and the seal on the box output shaft popped out and I can't figure out how the hell to get it back in. Any help?
A steering gear only has 2 shafts; the worm shaft (bolted to the steering column), and the Pitman shaft (I'll let you guess what bolts to that). No "output shaft" that I know of.
That said, the worm shaft seal is behind the adjuster and its locknut, so there's really no way for it to "pop out". The Pitman (or sometimes called "sector") shaft seals (there are 2) are behind a snap ring and some washers. VERY robust. They aren't just going to "pop out" either. Especially not from just going over a bump. Cars get ASTOUNDINGLY wrecked and the gear doesn't come apart like that.
Photos would help. Also let us in on a little bit of its history. This somehow doesn't sound like the first encounter this gear has had with human intervention.
A steering gear only has 2 shafts; the worm shaft (bolted to the steering column), and the Pitman shaft (I'll let you guess what bolts to that). No "output shaft" that I know of.
That said, the worm shaft seal is behind the adjuster and its locknut, so there's really no way for it to "pop out". The Pitman (or sometimes called "sector") shaft seals (there are 2) are behind a snap ring and some washers. VERY robust. They aren't just going to "pop out" either. Especially not from just going over a bump. Cars get ASTOUNDINGLY wrecked and the gear doesn't come apart like that.
Photos would help. Also let us in on a little bit of its history. This somehow doesn't sound like the first encounter this gear has had with human intervention.
I was referring to the pitman shaft. There is a rubber seal that goes around the outside of it, right above the pitman arm itself and surrounding the shaft on the exterior of the box. Fluid is leaking badly out of that seal as I have a feeling it should be tucked in, but it's protruding around the lip of the steering box casing where the pitman shaft comes out and meets with the arm. The box is a remanufactured one and has been on the car for only a few months. My finger is touching the seal in this photo
Last edited by 82Phoenix; May 11, 2025 at 06:51 PM.
I see the 2 seals and one of the 2 washers. I don't see either the lower washer or the snap ring that goes between it and the Pitman arm, and retains the seals.
Not sure that it's possible to get those seals to go back in there with the Pitman shaft installed. It's CERTAINLY impossible to put the other washer and the snap ring in with the Pitman arm in place.
I see the 2 seals and one of the 2 washers. I don't see either the lower washer or the snap ring that goes between it and the Pitman arm, and retains the seals.
Not sure that it's possible to get those seals to go back in there with the Pitman shaft installed. It's CERTAINLY impossible to put the other washer and the snap ring in with the Pitman arm in place.
I can take the pitman arm off and get to the seals, but the snap ring either fell out or straight up wasn't included with the new box. I think that's lawsuit worthy if they're leaving hardware out of crucial parts like this.
Edit: the reman box is an A1 Cardone unit, I've had nightmares with Cardone distributors and carbs before and I think I've had enough of them after this
Last edited by 82Phoenix; May 11, 2025 at 07:41 PM.
Reman boxes are usually an issue. They're usually resealed at best and as you have found out, resealed poorly. If you have your old box, send it out to a place like Lee power steering, they actually go through the box. Also, Borgeson makes a replacement that is a new, like not rebuilt, not resealed but new. Put one in my 82 and the steering has a more modern feel. The box is totally a bolt in. You need different length bolts and there is a metal "ear" that needs to get ground down to fit out cars. Borgeson is fully aware of the ear than need to be removed and it doesn't effect the warranty. It's a newer design box but the lines fit and the pitman arm/steering shaft bolt on. My 82 had the stock tight ratio box and the new box is a touch tighter ratio.
Reman boxes are usually an issue. They're usually resealed at best and as you have found out, resealed poorly. If you have your old box, send it out to a place like Lee power steering, they actually go through the box. Also, Borgeson makes a replacement that is a new, like not rebuilt, not resealed but new. Put one in my 82 and the steering has a more modern feel. The box is totally a bolt in. You need different length bolts and there is a metal "ear" that needs to get ground down to fit out cars. Borgeson is fully aware of the ear than need to be removed and it doesn't effect the warranty. It's a newer design box but the lines fit and the pitman arm/steering shaft bolt on. My 82 had the stock tight ratio box and the new box is a touch tighter ratio.
Even better, just take your old box, buy a rebuild kit, and do it yourself. That way you have no one else to blame. (or, no one who will screw up on your behalf and charge you for it, even if "blame" is not involved) They're really not hard. Just a part of a CAR which is one of the simplest most common mechanical assemblies on this miserable cosmic cinder we're all stuck on. So that's what I'd suggest; abandon this box, and renew your OE one.
One thing that I've always struggled with rebuild kits it the lack of ability to address the wear in the gears themselves. I believe the companies that rebuild them properly machine and use more bearings vs bushings and replace worn gears. Some make other support modifications on the pitman shaft to increase stability. Obviously not Cardone/napa stuff. But I believe Lee really gets into them w options for ratios/assist sensitivity etc. I've replaced everything in my car. There is nothing that is original less the wiring in some of the dash and the body itself. Out of all the parts I've replaced and tossed away, I kept my stock steering box. Because if I ever need to rebuild a box, I have one the I know is OK and worth rebuilding. So I agree w sofas point.
the lack of ability to address the wear in the gears themselves
This is very true. You can get the bearings; particularly, the large straight-roller thing that the Pitman shaft rides in; butt if any water has ever got into the gear, as often happens when the PS system is left uncovered for some reason, all the water goes to the very bottom of the system, which is THAT bearing. Then, since its inner race IS the Pitman shaft, kinda like an axle bearing, the shaft rusts too, and changing the bearing out doesn't renew it. The worm shaft and the ***** and all that hardly ever get any wear, but the Pitman shaft can be rendered useless; and since it's half of the arrangement that determines the ratio, it differs from one box to another, and can be quite difficult to source if a low-ratio ("fast") gear is desired.
In
Incredibly confused about this, there's a seal on the outside that I can't seem to get off (I took a chunk out trying to remove it) and it's not an OEM seal
I assume that's the reman box. They use weird seals to try and deal w variables in the used/worn boxes. That's part of why they are so unreliable.
that washer/seal thing is likely pressed on to hold the new/poorly designed seal in. I've seen that same thing on reman truck boxes.
this is the original box off my 82. The seal is totally different.
Yeah, my original box has the snap ring sandwich seals that it's supposed to have according to the '82 service manual. We're gonna get a Borgeson unit and I might keep the original box around if ever I may need it. Sick of Cardone parts constantly failing on me
Yeah, the Borgeson is a nice box. It bolts in. It needs 1/2 or 3/4 inch shorter bolts and needs the fourth bolt ear cut off. It's all pretty easy. Best part is, no special seals!
We ended up getting a MasterCraft box, it looks like it didn't come with ANY pitman shaft seals installed. Really getting irritated but at least I can install my own with the correct snap ring
