1st Gen steering coupler

[Kernel]

The infamous steering coupler on my first gen is done for, got to get it inspected this week, and I have one day (sunday) to get it fixed and drivable before I have to go back to work. Can I get the part from a place like Autozone and what kind of tools do I need and what can I expect? I tried a search and nothing came up on the availabilty of the part or how it is done. Any help is appreciated.



Scott

 

[B.G. Smith]

Gonna be hard to find on Sunday, NAPA might have it but most likely will be an overnight item. If not, try the big truck places tomorrow. bg http://www.honesdalenapa.com/

 

[Kernel]

Well I'm not going to get it done, thanks for the help bg. If anybody has tips for how to do the coupler, please PM me.



Scott

 

[B.G. Smith]

Mine (99) has two u- joints and a slip joint between them. I suspect yours is same or very similar. To remove, each u-joint has what they call a "pinch bolt through the fixed end where it connects to the steering shaft, this bolt must be completely removed as the shaft has a slot cut in it for the bolt so it can't come off even if the bolt is loose. You should be able to remove one end, slide the joint off the shaft then remove the other end. You can then remove the whole assembly from the truck and take it somewnere you can deal with it, like a large vise. Good luck. bg

 

[Parks]

IF you are talking about the coupler that connects the steering shaft to the box. The last time I tried to get one it was a dealer item only. They are a piece of junk. At the time I needed it I was not aware of anything to replace it but then I find out about Borgeson's steering shaft replacement which has a coupler more like a universal joint. They are not cheap but well worth it. Here is their webaddres : www.borgeson.com

 

[Andy Redmond]

The coupler is different from the 1st to second gen. The Borgeson is the way to go, in a pinch get the 50-60 dollar part from DC. Some penetrating oil and hand tools will fix you up in a hurry. Just a set screw and a through pinch bolt if memory serves. .



Its not hard unless rusted on real bad. If it scares you a shop or dealer would likely only charge and hour of time to change it out.



Good luck

Andy

 

[SteveMiller]

Wish I had taken pictures when I did mine but it wasn't hard. If you are going to try rebuilding it, once you get the shaft off the truck just pry up the tabs for the top piece of metal that holds it all in. when you pull it apart just be carefull and pay attention to how the peices of metal on the sides of the shaft are sitting.



I know this may sound a little redneck but I fixed mine with some aluminum from a pop can to get everything a little tighter. I wouldn't suggest driving it for too long like that but after looking at the joint and realizing what piece of junk it was I ordered the borgenson and just needed to get by until it showed up and I could replace it.



anyway, cut the aluminum to shim any areas that are noticeably worn down. Mine was around the steel dowel that went through the shaft that those pieces of metal went over. The rectagle metal pieces need to be able to swivel on that dowel but not have slop.



Don't know if this will help but good luck.



Steve

 

[BHiggins]

Go with the Borgeson unit as suggested by "Parks" I'm new to the T. D. R. but have owned Dodge Cummins Trucks for eight years (I'm currently on my third) The Borgeson unit was installed on my first truck after I replaced the stock one three times. You'll never replace it again!

 

[BJMarshall]

Borgeson definitely. 30 minutes to install and it works great. Very first thing I did when I got my truck.

 

[Kernel]

I went and got the rebuild kit from the *******, but where does the little 5/16" pin go? Is the roll pin for the housing? I haven't taken it apart yet because I have to get it to the DMV and figured I better limp in on it before I get it apart and make it worse.



Scott

 

[SteveMiller]

I think what your talking about with the 5/16" diameter pin(dowel) is what goes through the shaft down inside the coupler that those other rectagular pieces go over to rotate on. It seemed to me that those are what wear down the most and hence the reason I shimmed them temporarily. Those pieces having slop around that pin makes for alot of steering wheel movement.



Sorry for the total lack of anything resembling technical terminology.



I believe you just need to press that pin out and the new one in.

 

[Kernel]

There's a roll pin, a dowel pin, and a 5/16" long pin (really small). I figured the roll pin for the housing, the dowel pin that goes through the shaft with the metal pieces on each end, and the really small one for... . I don't have a press, how exact center does the steering shaft pin have to be?



Scott

 

[dodgenstein]

The really smallone goes into the side of the coupler body just below the rubber gasket/cover to keep the insides from sliding out. Once you get the coupler off you will see it.

 

[SteveMiller]

The pin will need to be fairyly centered. At the very least it can't stick out from those metal pieces on either side.



since I just replaced mine the borgenson I'm not sure how hard it will be to get out and put the new one in. I would probably try a socket and hammer method trying to be careful to not damage the shaft.



Steve

 

[Kernel]

Well, I got the coupler about 90% done, ran out of light and had to stop. I got it packed with grease and finally got the shaft put into the housing. I guess it only goes in one way. When it came apart the metal "spring" was sideways, but I found it doesn't go in that way. It seemed like it only would slide in one way with the spring on the end of the shaft. Is this right? I guess it stayed together, it felt like it slipped in like it should and is tight. This was about the time it was getting dark under the fender well. I couldn't get the pin out of the shaft itself, tried to use a socket and a vise but all it did was press the socket into the shaft and made a couple of grooves. I filed it smooth and just used the old one. The blocks fit on it with no problems. All I have left is to put the cap on it and bend down the tabs. Hopefully tomarrow will go better.



Scott

 

[Kernel]

Okay, got the thing together, went for a ride and now it drives worse than it did before. It hangs up in turns, especially right turns, and doesn't want to naturally come out of them. It doesn't pop in sharp turns anymore, is tight, but hangs up.



WHAT GIVES?





Scott

 

[Kernel]

Darkness + Texas Heat + Mosquitos = Mess-up.



That sums it up. I took it back apart and figured out I put it in wrong... what a PITA. Now it steers a lot better, and is tighter than my 97. The cap is not on the tightest, but heck with it, I think the next time it comes off a borgeson is going back on. Thanks for your help guys.



Scott