DII Steering box replacement

[hrrovr1]

Looks like I may have a need to replace the Steering box on my 1999 DII. On a scale of 1-10, 10 being most difficult, how tough a job is this. Just trying to see if I can leverage my intermediate mechanical skills to save a few bucks. Qualified shops in this area are few to none.

Symptoms are a severe groaning, which appears to be coming from air in the fluid. It has been diagnosed as a leak in the low pressure line, which I assume is coming from bad seals or o-rings. I can see fluid coming from the forward line in the top of the box. It is a significant leak. I am replacing all four of o-rings on the lines on top of the box in hopes this will do the job, but have been told I should be prepared to replace the box. Any help would be greatly appreciated.

 

[scottagnew101]

I would say maybe a 3 out of 10. Its a little time consuming and I would strongly advise having someone help you put the new one in. Taking it out is not hard by yourself, but lifting all that weight and trying to get the bolt holes lined up were a pain (assuming you are going to be working on the ground). All-in-all plan on 3-4 hours (working leisurely taking your time; ie: not being rushed) including bleeding the system and adding new fluid.


I did mine as so.

1.) Draining the fluid from the PS tank, then undoing the hoses and draining them as well.
2.) undo the TRE on the steering arm (maybe do this first in-order to make sure you can remove the linkage from the box? before you go too far?)
2.1) Remove the steering linkage that goes from the back side of the fire-wall and into the box. Should be 2 bolts, one you will loosen (its a torx head close to the steering box) and it will allow it to slide up and take up any slack in the system with a complete removal.
3.) Take off the plastic shroud from the driver side (facing the outside of the frame) (you might need to turn your wheel or possibly take it off, but be sure to secure it with jack-stands!)
4.) remove the 3 bolts holding the box to the frame.
5.) Drop the old box.
6.) install the new box (reverse)
7.) bleed system and install fresh fluid.

Did I miss anything? - Oh enjoy a beer between every step

 

[KyleT]

get a good used one or a brand new one, not a LR rebuilt one, they wont last and leak like crazy, I went through 6 of them...

and the 03-04 do not have steering stops built in, which may be why they blow the seals so bad...

its about a 2 in difficulty, take the panhard rod off or you will tear the bushings.. i did once...
make sure to put a bolt in the box to hold it straight too.

 

[scottagnew101]

make sure to put a bolt in the box to hold it straight too.

AHH yes! although I did not take off the pan-hard bar, is that really necessary?

You will see on the back of the steering arm a notch that's cut out, which goes into the body/housing of the box with a hole, thread a bolt in that to make sure your steering will be straight.