Steering box knocking after drilling for hydro assist

Mathis Photography

Active Member
Joined
Apr 28, 2009
Location
Wilmington, NC
This weekend I took my steering box (Astrovan box, standard saginaw style) apart and drilled/tapped it for hydro assist lines. I was sure to get all of the shavings out before reassembly. Everything went together as it should and I put it back on the truck. Now at about 1/4 turn before full lock to the left it pops and then completes the turn. It does it even when disconnected from the drag link.

The steering wheel is also roughly 1/4 turn off, which doesn't make sense. As I'm going through the process in my head, the only thing that seems possible is that the power piston isn't lined up properly, but from my limited knowledge, it doesn't seem like it would all go back together and function if it isn't lined up.

I drove it around the block last night and it seems to be functioning properly and isn't leaking. Just making the pop and the steering wheel is off. I can fix that with the drag link, but it doesn't leave enough of the heim shank in the shaft.

Anyone have any ideas? I'm hoping to get some guidance before I take it all off again and pour another quart of fluid in the floor of my garage.
 
The pop could be coming from the sector shaft gear meshing with the mating part. Is it adjusted properly?

The steering wheel could be off from the pitman arm not going back in the same location as it was. I know a lot of them have 3 or 4 master splines and can only go on 1 of 3/4 ways, but some of the aftermarket pitman arms are fully splined and you can get them a tooth or two off without realizing it. If you didn't mark it and put it back in the same orientation, then it very well could be off. Not sure what vehicle you're dealing with, but some of the stubs that the steering shaft bolts/clamps to are also fully splined and it could be off there as well. Then again, many of them have a flat on them or something such as that and will only go on a certain way.

If everything was fine before, then something got misaligned in the reassembly process.
 
I didn't change the adjustment, so I assume it is adjusted properly. Pitman arm can only go on 4 ways, and 1/4 off on the pitman arm would put it parallel with the axle when 'straight.' The steering shaft clamp has a flat spot and only goes on one way.

The box is from an Astrovan, using all stock components.
 
That's odd... maybe it has something to do with the recirculating ball deal that's on the main shaft. That's the only thing I can think of.
 
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