Attention: TDR Forum Junkies 
Sorry all just now (2/26/18) realized when I was typing the title I had a finger slip = 04-02 should be “94”-02 - D’oh!
This all started on 11/12/17 when I read a thread started by RRasch on 11/7/18 titled "No more Borgeson steering boxes for 2nd gen Dodge?". My original steering box @ 230k mile was "past it" and leaking, I thought about rebuilding it myself and within RRasch's thread acquired some advice, I read the shop manual on the rebuild procedure and decided to order up a PSC unit from Geno's - I ordered it late Dec. 2017.
On 2/19/18 I received the “59 lbs.” PSC unit, apparently the reason it took almost 2 months to arrive is because PSC was making modifications. It is huge compared to the stock box.
2/21/18
I began installation, I say “began” as I ran out of light and it started to rain last night. What a RPIA hefting that thing up and down out of the chassis to see what was interfering with it going up and in. I left the box hanging in there by one bolt, thank god at least, hopefully, I’m done with bench pressing the unit up and down, fighting with the creeper from creeping down the driveway (gave up on using the creeper) and fighting the floor jack from creeping down the driveway while trying to get a bolt thru the chassis to the box as well. It is “not” a direct R & R in the classic sense as it appears (in the dwindling light and from what I could see with a drop light) that the fluid lines from the pump will need to be tweaked from hitting the wiring harness along the timing cover, or the harness might need to be moved, or both, not totally sure as of yet, hope to know more today if the rain holds off. Also, the trans lines to the rad are right on the side of the box and will need to be bent out of the way, not sure about the pitman arm to drag link mounting hole yet = it appears to be a tapered hole but looks smaller that the original so I might need to take the old arm and new one to a machine shop for matched tapering of the hole, I hope not....???? A few notes for those that have not yet installed the PSC box:
1- If you don’t have an 1-13/16” socket get one now, NAPA had in-stock @ $27. None of the local to me parts stores near me (Autozone, Etc.) had in-stock nor did HomoDepot or even Sears.
2- PSC doesn’t include installation instructions. I “guess” it’s supposed to be a direct R & R = not.
3- Plan on getting someone to help install that first bolt - although 59# isn’t really heavy if you’re laying on your back trying to heft it in and out it might as well be a ton.
4- Plan on tweaking the trans lines and possibly moving the wiring harness that runs along the side of the timing cover.
5- If you haven’t already extended or otherwise addressed the puke hose (a.k.a. = Dodge auxiliary chassis lubrication system) from the timing cover now would be a good time.
More to come once complete.
2/22/18 I called PSC around 10:45 Eastern time to ask “a few” questions, such as: why a $700 non-stock box doesn’t include some sort of installation tips/instructions. And to seek info on some other things I’d like to know. Not totally ****** off yet, I was prepared when I opened the box and eyeballed the whole job to see how much “fun” it was going to be, just a bit un-nerved that there were no instructions.
PSC Tech Support (Kelvin) was very pleasant and seemed knowledgeable. He explained that the modifications were so new they had not yet developed instructions. I asked about the spacers. He said they go between the box and the frame unless I get lucky and it bolts right up. I asked if the stock torque specs should be used or if they offered specs. He said stock will be fine.
So today's progress:
Determined spacers had to be used. Frame would have interfered with the top edge of the box.
Removed the wiring harness strap screws along the timing cover and move the harness rearward as much as possible because the "straight" 2-3" long return fluid line would have penetrated the harness.
Thank god I had at least one bolt threaded into the box. A real RFPIA trying to finesse the other two, with spacers between box and frame = pry this a bit, wedge that a bit, get an extension magnet and feed the top spacer in then go back under and see if the bolt will go thru the spacer, then wiggle and pry away a bit more to line up and catch 4 or 5 good turns. From there the other two were easier, buy by no means a cake walk... Got the 3 bolts snugged up so the box is tight to the frame.
Now the easy part, or so I thought, connecting up the slip shaft from the column to the box input shaft. WHAT!!?? It's too short, ARGH!!! Well my shaft don't slip no more so, out it came, lots of penetrating fluid and tapping on the ground then loosely stick in the bench vice and pull the other way (sort of like using a dent puller) after a while it budged enough to wire brush some of the rust off, and then more pen-oil, tap, pull, wire brush until it slipped pretty freely. Feed in grease, slid in/out, more grease, etc.
So, I went back out to give her a go and don't you know Mother nature decided I was done for the day, letting me know this by the downpour that began. Thanks Mom, really, I've had enough by that time anyway.
More to come... tomorrow, weather permitting...
This all started on 11/12/17 when I read a thread started by RRasch on 11/7/18 titled "No more Borgeson steering boxes for 2nd gen Dodge?". My original steering box @ 230k mile was "past it" and leaking, I thought about rebuilding it myself and within RRasch's thread acquired some advice, I read the shop manual on the rebuild procedure and decided to order up a PSC unit from Geno's - I ordered it late Dec. 2017.
On 2/19/18 I received the “59 lbs.” PSC unit, apparently the reason it took almost 2 months to arrive is because PSC was making modifications. It is huge compared to the stock box.
2/21/18
I began installation, I say “began” as I ran out of light and it started to rain last night. What a RPIA hefting that thing up and down out of the chassis to see what was interfering with it going up and in. I left the box hanging in there by one bolt, thank god at least, hopefully, I’m done with bench pressing the unit up and down, fighting with the creeper from creeping down the driveway (gave up on using the creeper) and fighting the floor jack from creeping down the driveway while trying to get a bolt thru the chassis to the box as well. It is “not” a direct R & R in the classic sense as it appears (in the dwindling light and from what I could see with a drop light) that the fluid lines from the pump will need to be tweaked from hitting the wiring harness along the timing cover, or the harness might need to be moved, or both, not totally sure as of yet, hope to know more today if the rain holds off. Also, the trans lines to the rad are right on the side of the box and will need to be bent out of the way, not sure about the pitman arm to drag link mounting hole yet = it appears to be a tapered hole but looks smaller that the original so I might need to take the old arm and new one to a machine shop for matched tapering of the hole, I hope not....???? A few notes for those that have not yet installed the PSC box:
1- If you don’t have an 1-13/16” socket get one now, NAPA had in-stock @ $27. None of the local to me parts stores near me (Autozone, Etc.) had in-stock nor did HomoDepot or even Sears.
2- PSC doesn’t include installation instructions. I “guess” it’s supposed to be a direct R & R = not.
3- Plan on getting someone to help install that first bolt - although 59# isn’t really heavy if you’re laying on your back trying to heft it in and out it might as well be a ton.
4- Plan on tweaking the trans lines and possibly moving the wiring harness that runs along the side of the timing cover.
5- If you haven’t already extended or otherwise addressed the puke hose (a.k.a. = Dodge auxiliary chassis lubrication system) from the timing cover now would be a good time.
More to come once complete.
2/22/18 I called PSC around 10:45 Eastern time to ask “a few” questions, such as: why a $700 non-stock box doesn’t include some sort of installation tips/instructions. And to seek info on some other things I’d like to know. Not totally ****** off yet, I was prepared when I opened the box and eyeballed the whole job to see how much “fun” it was going to be, just a bit un-nerved that there were no instructions.
PSC Tech Support (Kelvin) was very pleasant and seemed knowledgeable. He explained that the modifications were so new they had not yet developed instructions. I asked about the spacers. He said they go between the box and the frame unless I get lucky and it bolts right up. I asked if the stock torque specs should be used or if they offered specs. He said stock will be fine.
So today's progress:
Determined spacers had to be used. Frame would have interfered with the top edge of the box.
Removed the wiring harness strap screws along the timing cover and move the harness rearward as much as possible because the "straight" 2-3" long return fluid line would have penetrated the harness.
Thank god I had at least one bolt threaded into the box. A real RFPIA trying to finesse the other two, with spacers between box and frame = pry this a bit, wedge that a bit, get an extension magnet and feed the top spacer in then go back under and see if the bolt will go thru the spacer, then wiggle and pry away a bit more to line up and catch 4 or 5 good turns. From there the other two were easier, buy by no means a cake walk... Got the 3 bolts snugged up so the box is tight to the frame.
Now the easy part, or so I thought, connecting up the slip shaft from the column to the box input shaft. WHAT!!?? It's too short, ARGH!!! Well my shaft don't slip no more so, out it came, lots of penetrating fluid and tapping on the ground then loosely stick in the bench vice and pull the other way (sort of like using a dent puller) after a while it budged enough to wire brush some of the rust off, and then more pen-oil, tap, pull, wire brush until it slipped pretty freely. Feed in grease, slid in/out, more grease, etc.
So, I went back out to give her a go and don't you know Mother nature decided I was done for the day, letting me know this by the downpour that began. Thanks Mom, really, I've had enough by that time anyway.
More to come... tomorrow, weather permitting...
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