rustystud
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I'm in the process of reworking some steering gears for a project I've been working on. I thought some here might want to know how to fit their bushings without the aid of fancy "burnishers" and "reamers" .
Now normally you would use a "reamer" (pictured here) to size your new bushings or a "burnisher" . Since most people don't have that in their shop I'll show you how to fit (size) your bushings with a brake hone.
Using a drill or drill press and some good cutting oil start honing the bushings. You should also buy the most course hone stones you can find. It will cut much faster if you do. Use a lot of cutting fluid on the stones.
After several passes, clean the bushings ( I use brake clean) then check you progress by trying to insert the "sector shaft". Keep going until you are able to start the sector shaft. Then using a "rubber mallet" try and insert the shaft as far as you can. Then remove it again using only the rubber mallet (never use a hammer on the sector shaft !!!! ) .
What you will see is dark spots on the bushings. These areas need more grinding (sanding) and you should concentrate your honing there. After you are able to totally insert the sector shaft, twist it several times. Then after removing it check for any dark spots. Now you can just use some fine (200 grit and finer) sand paper to touch-up these areas.
In the end what your looking for is to be able to fully insert the sector shaft and be able to turn it by hand fairly easy. I say fairly easy as you want "ZERO" play in the shaft.
The primary cause of oil seal failure is worn sector shaft bushings. According to the TM the amount of clearance you need is in the hundred thousandths of an inch . That's 0.0005 kind of clearance.
It will take several hours of work, but in the end you will have a perfectly fitted sector shaft in your steering gear.
Now normally you would use a "reamer" (pictured here) to size your new bushings or a "burnisher" . Since most people don't have that in their shop I'll show you how to fit (size) your bushings with a brake hone.Using a drill or drill press and some good cutting oil start honing the bushings. You should also buy the most course hone stones you can find. It will cut much faster if you do. Use a lot of cutting fluid on the stones.
After several passes, clean the bushings ( I use brake clean) then check you progress by trying to insert the "sector shaft". Keep going until you are able to start the sector shaft. Then using a "rubber mallet" try and insert the shaft as far as you can. Then remove it again using only the rubber mallet (never use a hammer on the sector shaft !!!! ) .
What you will see is dark spots on the bushings. These areas need more grinding (sanding) and you should concentrate your honing there. After you are able to totally insert the sector shaft, twist it several times. Then after removing it check for any dark spots. Now you can just use some fine (200 grit and finer) sand paper to touch-up these areas. In the end what your looking for is to be able to fully insert the sector shaft and be able to turn it by hand fairly easy. I say fairly easy as you want "ZERO" play in the shaft.The primary cause of oil seal failure is worn sector shaft bushings. According to the TM the amount of clearance you need is in the hundred thousandths of an inch . That's 0.0005 kind of clearance.
It will take several hours of work, but in the end you will have a perfectly fitted sector shaft in your steering gear.
