Steering box replacement

[Jengle]

Replacing the steering box on my 2004 and got the old one out, new one mounted, and lines in place. But for the life of me, I can't get the steering shaft to go onto the spindle for the steering wheel. The shafts are the same size, measured with dial calipers, and it slipped on once, but the bolt wouldn't thread. I took the shaft off and the bolt threads like it should, but the still the coupler won't slip back over the shaft, and this is with the bolt removed. I know it won't go on with the bolt in place. I fought with it for 2 hours and never got it close to going on.

Anyone got a tip to help get this thing back on?

 

[goodguys75]

what brand of box did u get?

 

[Jengle]

NAPA. I also got their U-joints for the front axles and their ball joints. They also had the tools to loan for pressing out the ball joints. Same tool for the u-joint removal.
It was a bear getting the axles out. Our snow removal efforts caused that.

 

[AKorn]

Is there any type of notch on the spindle of the factory box? If so, does the NAPA box have the same notch? I'm wondering if the coupler wasn't pushed onto the spindle all the way. The bolt hole on the coupler would need to line up with the notch on the spindle.

FYI I'm making an assumption that there's a notch on the spindle, since I haven't actually changed out the box on my truck. I have replaced a box on an old Jeep that I had, and just thought it might be similar.

 

[Jack in Alaska]

My steering box was replaced with a NAPA box. I had it done by a local mech. He had no problems. It works well.