Attention: TDR Forum Junkies 
We just wrapped up replacing the steering gearbox on Jacob's '97 3500. Definitely not one of my favorite projects, messy, dirty, MULTIPLE trips for more stuff.
Drivability complaint: Drifting or loose feel and wandering. 168,000 miles, Toyo's showing cupping on outer and inner edges. Front end inspection shows two areas needing attention, Idler Arm (replaced 3 weeks ago) and the pitman arm shaft moved "laterally" as you worked the steering wheel back and forth. I contemplated adjusting the gearbox, but chose to replace it with a reman.
Tools purchased, 33mm socket for pitman arm nut, 18mm open end for various line connections. New 3 1/2T floor jack (30 year old Sears finally died) 4T jack stands.
Parts list. Reman gearbox for 3500, two pressure lines, one 11/32" PS return it is actually listed as a part, not from the bulk hose section, several clamps, inline PS filter (looks like old inline gas filter) the remanfg'r recommend an internal inline filter but it looked chincy and mickeymouseish, opted for expensive inline, and of course oil dry.
Big issues, handling gearbox with lines already attached. These lines use an o-ring on the steel tube, easy to muck up, be careful, thats why I put them on the box on the bench. Biggest issue, bleeding the air out of the system. Dodge manual recommends multiple stop to stop cycles to purge air, keep checking reservoir. I'd say expect to see foaming as the air churns out. Do not let the pump run dry. It took a while to get it to get the foam out and start working correctly.
Test drive: seems tighter, need to put more casual miles on it.
Most interesting pass along comes from the tag on the gearbox.
"ATTENTION Steering Gear Pitman Shaft Movement.
Most power steering gears are built with a roller bearing that supports the pitman shaft while allowing it to rotate. Force placed on the pitman arm by the suspension transfers to the pitman shaft. The roller bearing is designed to absorb this, but a NOTICABLE amount of lateral movement may be observed. This is a normal characteristic of a roller bearing when used in this application"
No easy way to measure it, but you can still see "lateral movement" in the new box, like to old one, but it steers better. Will need professional alignment and ???
Not a fun job, we didn't need oil dry when we fixed the KDP on this truck.
Disclaimer, not trained on the job, just read the manuals and School of Hard Knocks Degree in Applied Wrenchology, working on my minor in Cummins.
Drivability complaint: Drifting or loose feel and wandering. 168,000 miles, Toyo's showing cupping on outer and inner edges. Front end inspection shows two areas needing attention, Idler Arm (replaced 3 weeks ago) and the pitman arm shaft moved "laterally" as you worked the steering wheel back and forth. I contemplated adjusting the gearbox, but chose to replace it with a reman.
Tools purchased, 33mm socket for pitman arm nut, 18mm open end for various line connections. New 3 1/2T floor jack (30 year old Sears finally died) 4T jack stands.
Parts list. Reman gearbox for 3500, two pressure lines, one 11/32" PS return it is actually listed as a part, not from the bulk hose section, several clamps, inline PS filter (looks like old inline gas filter) the remanfg'r recommend an internal inline filter but it looked chincy and mickeymouseish, opted for expensive inline, and of course oil dry.
Big issues, handling gearbox with lines already attached. These lines use an o-ring on the steel tube, easy to muck up, be careful, thats why I put them on the box on the bench. Biggest issue, bleeding the air out of the system. Dodge manual recommends multiple stop to stop cycles to purge air, keep checking reservoir. I'd say expect to see foaming as the air churns out. Do not let the pump run dry. It took a while to get it to get the foam out and start working correctly.
Test drive: seems tighter, need to put more casual miles on it.
Most interesting pass along comes from the tag on the gearbox.
"ATTENTION Steering Gear Pitman Shaft Movement.
Most power steering gears are built with a roller bearing that supports the pitman shaft while allowing it to rotate. Force placed on the pitman arm by the suspension transfers to the pitman shaft. The roller bearing is designed to absorb this, but a NOTICABLE amount of lateral movement may be observed. This is a normal characteristic of a roller bearing when used in this application"
No easy way to measure it, but you can still see "lateral movement" in the new box, like to old one, but it steers better. Will need professional alignment and ???
Not a fun job, we didn't need oil dry when we fixed the KDP on this truck.
Disclaimer, not trained on the job, just read the manuals and School of Hard Knocks Degree in Applied Wrenchology, working on my minor in Cummins.
