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Discussion Starter #1
I bought the abovementioned steering gear box and am trying to install it. I've run into two problems:
1. The new steering gear is about 1-7/8" longer than stock.
2. There is an ear on the upper/front end of the new steering gear that interferes with the front frame crosstube.

It looks like I can shorten the lower steering shaft, but I need a little advice on removing it and modifying it. I may be able to grind away part of the ear on the steering box enough to allow the upper bolt to line up. Advice and pictures? Thanks.

JK
 

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Discussion Starter #3
I did send them an email. Being Christmas Eve, I figured it might take a couple of days to respond. In the meantime, I've got everything removed and cleaned up. One question, though. I read somewhere about the clocking of the steering wheel. It has apparently flipped 180 aince I pulled the box. Is this a problem? If so, how to fixi it?

JK
 

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Yes, you have to watch that!!!! It will take out the Clock Spring. And once they are gone, it's gone. You have to replace it and they are expensive and can be a big PITA!

You might not have done any damage yet. If possible, put the wheel back where it was and then use rope, a bungee or something and tie it so that the wheel will not move. Just be careful, you don't want to turn the wheel too much. Just try to get it back to where it was if you know which way it turned.
 

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SweetPee said:
Yes, you have to watch that!!!! It will take out the Clock Spring. And once they are gone, it's gone. You have to replace it and they are expensive and can be a big PITA!.............
I doubt a single 180° will do any damage but, it's possible. I've had mine apart 2-3X and there's plenty of leeway for even a 360°. I have heard of them being repaired by soldering. The only PITA is locating a T9 driver to take them apart and reassemble them.
 

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Discussion Starter #7
f9k9 said:
SweetPee said:
Yes, you have to watch that!!!! It will take out the Clock Spring. And once they are gone, it's gone. You have to replace it and they are expensive and can be a big PITA!.............
I doubt a single 180° will do any damage but, it's possible. I've had mine apart 2-3X and there's plenty of leeway for even a 360°. I have heard of them being repaired by soldering. The only PITA is locating a T9 driver to take them apart and reassemble them.
How will I know if there is a problem?

JK
 

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to shorten the shaft, just drill out the plastic pin and then collapse the shaft some. If you go too far, pull it back out. Thats how I did mine.
 

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Discussion Starter #9
Mouse said:
to shorten the shaft, just drill out the plastic pin and then collapse the shaft some. If you go too far, pull it back out. Thats how I did mine.
I have yet to find the plastic pin. Where is it on the lower shaft? Do I need to remove the lower shaft? Also, what is a clock spring and where is it located?

JK
 

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The clock spring is within the steering wheel. It is what allows the wheel to turn and keep electrical contacts for the cruise control, air bags, trips the turn signals, etc....

Like F9K9 said, I doubt you have broken anything yet. Now if you turned the wheel several revolutions... That might present a problem. Generally if they go bad or break IIRC the jeep wil throw a code due to the airbag system.
 

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Discussion Starter #12
Thanks SweetPee. I've saved the images and will print them. I may not have a problem with the clock spring because the steering column has been locked since before this part of the upgrades started. I started out to replace axles and balljoints, then install the PSC pump, steering gear and Deralle fluid cooler. Beginning with the axles, Jeep in Park, I removed tires/wheels axles, knuckles, tie rod and drag link. At that point, everything was on jack stands and the stock steering gear still installed. After axles, balljoints etc. were done, I reinstalled the passenger side tire and wheel and left the driver side open to work on the steering gear. I don't see how the steering wheel could have possibly moved. Another clue was that the all of the bolts on the steering shaft were in perfect top and bottom positions, as were the two plastic plugs I drilled out with the shaft still mounted. For extra measure I seatbelted the steering wheel down.

Now, I need to remove the lower streering shaft and collapse it and think about grinding off the ear on the top/front of the PSC steering gear so I can install the whole mess and figure out the plumbing. I was able to drill out the two plastic plugs with the shaft still installed, but I can't get it to collapse. The photo shows the offending ear at the bottom of the picture. incidently the picutre of this steering box shows the ear ground flat for the 03-06 TJ.

 

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Discussion Starter #13
I got on PSC's website and discovered everything I ordered through a popular reseller is wrong! Steering gear and Pump are getting returned Monday! In the meantime, I'll figure out the steering shaft issues. Thanks for the help!

JK
 

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Discussion Starter #15
That's my plan. I'll call them Monday right after I ship all of this garbage back to Quadratech. I'll need their advice on plumbing in the cooler and all. Thanks. You've been a great help.
 

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2JK said:
Mouse said:
to shorten the shaft, just drill out the plastic pin and then collapse the shaft some. If you go too far, pull it back out. Thats how I did mine.
I have yet to find the plastic pin. Where is it on the lower shaft? Do I need to remove the lower shaft? Also, what is a clock spring and where is it located?

JK
I looked for a pic of mine but couldn't find one. It just looks like a spot of plastic on te otherwise metal shaft - will be close to where the two sections meet.
 

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Its easier to remove the lower shaft. Between the support on the frame and the firewall, should be a 13mm bolt that holds the lower section to the upper. Remove this bolt, and pull the lower section out.

As Mouse said, look for some sort of difference in the metal where the two sections meet. You can normally feel it. Once you find it, just sand it down a little and the white plastic will quickly show. Drill that out, and spray drip some oil and everything should collapse easily.
 

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Discussion Starter #18
Thanks Phillip. I was able to drill out the plugs with the shaft still installed. Couldn't collapse the shaft, though. I'll have to remove the lower shaft as you mentioned and give it a nudge. The good news in all of this is that the upper and lower shafts seem to be tight. I tried rotating them back and forth by hand and got no slack. Of course the steering column is locked, so that end is rigid and gave me a good test to wiggle against.

JK
 

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JK,

I have driven by a PSC shop on 730 South in Azle, Tx, just outside of Fort Worth. I don't know if that is there main shop, I know you can't take the Jeep up there, but that isn't too far from El Paso. I really like doing business with folks when I can talk to them face to face. Good Luck on the install.
 

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Discussion Starter #20
Resqtek said:
JK,

I have driven by a PSC shop on 730 South in Azle, Tx, just outside of Fort Worth. I don't know if that is there main shop, I know you can't take the Jeep up there, but that isn't too far from El Paso. I really like doing business with folks when I can talk to them face to face. Good Luck on the install.
I tried calling them this morning, but they are closed for the Holidays. Anyway, I placed my oredr online and they'll get it when they return. The non-Texans here will love this. Its a 10 hour drive from here to Azle, mostly on interstate highways. That's only about 2/3's the width of the state. Its 14 hours from here to Texarkana at the other end of the state from us.
 
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