steering box crack

[ABachar]

After having my frame welded up, 8 months down the road I found that a bolt had popped off at the nut, and one of the ears from the steering box had cracked clean through. After putting another box on this has happened again, yesterday.



My guess is that there is some problem with the seating of the box on the frame that is causing the same break to identical boxes. I feel that if I just put another box on this will happen again. Any thoughts? Will a different brand of box for 4wd's (say PSC) prevent this?



My truck is 4wd and has crossover steering. I have it lifted 6 inches in the front, and 32" by 10" tires. I dropped down from 32" by 12. 5" tires recently. About the only off roading I do is driving the river bars looking for fish. Thanks.

 

[ABachar]

Here are some pics.

 

[KOG]

The frame must be FLAT where the box mounts. It appears the the welding job isn't allowing the ear on the box to have flat support.

 

[ABachar]

Thats basically what I thought. So how do I get it flat? I was under the impression that the beads of the welds should be left alone. I don't think I should grind the welds or frame down to fit, or can I?

 

[PToombs]

I agree! The welds must be ground down, at least where the box sits.

If you don't want to do more than necessary, mark the outline with a soap stone or white marker. Then grind just where the box contacts the frame.

Did you box the frame? I've read that is the hot ticket, especially for crossover setups. It stiffens the frame alot in this area.

Good thing for digital cameras, huh?

 

[KOG]

Yes, you can grind the beads. Reinforce the frame on the back side as needed.

 

[ABachar]

Good thing for digital cameras, huh?

Yep, and good thing for TDR. Thanks guys. The back and inside bottom of the frame is reinforced, though not boxed.

 

[DVolk]

One thing you can do to add some strength to that weak set up



is get a 1/4 to 3/8 plastic coated cable make a loop at one end



wrap the loopend end on the front side of the gear box and insert the other end of cable through the the loop were the notch is on the gear box by the swing arm(pitman arm ) so that there is clearence. Make anouther loop at the other end

of the cable , (you need around 3 to 4 feet of cable ) .



get a eye bolt and install in the conveint hole already on the passenger side of frame , get a turn buckle with a jam nut set up so it dont back off between the eye bolt and cable and tighten it up until the cable is really taunt , after 3 weld jobs mine is holding for now

 

[ABachar]

DVolk,
I remember you posting about this remedy before, and I think I still have pics of your setup. This time I will try this. Before I had a diagonal brace welded from the back of the reinforcing plate and bolted to the frame cross member. This eventually ripped out at the plate. My guess is that the frame still needs to flex a little bit and this setup was not allowing it, so it worked through. Your setup seems like it would hold the box tight/flush to the frame (which is my problem now), yet let the frame flext a bit. Thanks again.

 

[DVolk]

No problem , now if i could just fix the other problems with my truck from abuse mainly from the previous owner long time ago