2nd Gen Non-Engine/Transmission Borgsen Steering Shaft can kill you

[rootmanslim]

Well smart guys we now have a SECOND recorded failure here in Wyoming. This one was on a 2000 2500 4x4 and did the same thing mine did. Lock nuts backed out, set screw came loose and steering wheel became free floating. As I said ( and contrary to the dumb azz remarks) the design is faulty and could be fixed by the maker with the simple addition of a safety wire. The company knows about the problem (I sent them photos), they don't care, they don't have to as aftermarket parts receive no oversight from the NHTSA. It's your butt, not my problem. As we all know the Hindenburg made many, many flights before blowing up, but blow up it did. I drove probably 4000 miles with that POS between my family and I going off a cliff. It provides NO, NADA, ZERO advantage over the stock setup when the truck is equipped with a Solid Steel steering box stabilizer and a Luke's Link. Stupid is as stupid does ...... I saw the light w/o a train wreck !

 

[fest3er]

Still seems odd to me that properly torqued set screws and lock nuts came loose. Especially with thread locker on them.

 

[MMeier]

Still seems odd to me that properly torqued set screws and lock nuts came loose. Especially with thread locker on them.

X2. ! What he said !

 

[monkeyman]

about five years ago with same shaft I was going down a major street and lost steering going about 30, my first thought was something snapped, I was able to drift to side and saw allen lock screws backed all the way out and shaft separated. I ran back to my shop three blocks away we had red lock tight, which should have been supplied in kit. I squirted some in holes and threads, has not budged yet, However if you put a clamp type bracket on shaft like those welded turbo hose clamps even if screws come loose it cant separate
Rick

 

[Tuesdak]

Thanks for the heads up. I'll have to inspect mine often on the Hot Rod now.

 

[Tuesdak]

And one more thanks for the heads up. I owe you guys one!

My 1993 Chevy failed the pre trip inspection. I noted the Borgeson shaft was loose at the steering column. It had a 'pop' in the steering that you could feel, but, not track down.

Turns out it would jam up tight from torque of turning the wheel and stay tight till you turned the other direction. It would then get loose and tighten on the other side. It was slowly working it's way off the shaft. Managed to catch it, finally, in the loose position.

Both set screws bolts were not loosing up. Rather they were bending the hollow column shaft under the set screws making a channel to slide off.

It really needs a hole drilled through it and a bolt to stay in place like the factory design.

 

[petersonj]

First of all, I have to agree that using set screws for clamping the connections when installing a Borgeson steering shaft is not the best application. It would probably be okay in different application, such as a PTO driveshaft where the attaching shafts on both ends are solid, the duty cycle is intermittent, and the risk of serious harm is minimal in the event of a failure.

JDoremire noted that the steering column shaft on his truck was hollow and that the set screw actually deflected the metal. I noted that steering column shaft on my truck is hollow, as well. In these scenarios, a set screw will not remain tight. Some say to use Loctite. Although a loctited set screw won't move, the steering connection will still become loose and will start moving around because of the metal deflection in the hollow shaft. The loctited set screw will buy you more time, but eventually the connection will fail.

After installing the Borgeson steering shaft on my truck and during 25,000 miles of driving, all of the set screws have remained tight EXCEPT the two set screws that joined the upper part of the Borgeson steering shaft to the steering column shaft (the hollow one). At one point they had become very loose. This is obviously the most critical connection because under the right conditions gravity will take over and others have posted what can happen when this connection fails.

That said, here are some tips that might help reduce the chance of the set screws coming loose. During installation be mindful of the following, especially on the upper connection:

1. When sliding the upper part of the Borgeson steering shaft onto the lower steering column shaft be very careful not to slide it on too far. If this happens the u-joint yokes may push against the end of the steering column shaft in certain steering positions. You may or may not feel this in the steering wheel. These axial forces will cause undue stress on the steering column and the set screws will loosen.

2. Inspect operation of the slip yoke on Borgeson steering shaft. If it is difficult to move, the same axial forces mentioned above will occur. (See my previous post "Borgeson Steering Shaft (2002 2500 4WD) - Modification after 25,000 miles of driving" for more details).

3. Follow the instructions using the Borgeson steering shaft installation guide.

4. After the installation is complete and you are back to driving your truck, use only enough steering force to get the job done. What I mean is this - many times you are maneuvering in a tight spot and you need the full travel of the steering wheel. When you get to either the left or the right steering limit, back off just slightly to reduce the forces on all of the steering components from the steering wheel to the steering gear box, which includes that pesky connection with the two set screws. If you are one of those who holds the steering wheel hard against the stop during these maneuvers, not only will you be providing unnecessary force, you will also probably be replacing hoses and pumps long before the other guy because this method will cause the power steering fluid to go to maximum pressure and pass over the relief valve for the duration of the maneuver. The rapid excessive heat buildup destroys power steering pumps.

4. Inspect the set screws (especially the upper ones) on a regular interval.

5. If you have the time, install a redundant steering wheel on the passenger side of the truck. Make sure it is within reach.

- John