my new steering gear box won't reach the rag joint coupling

[Skoolie 89]

I have a 1989 Ford E350 Skoolie ( Thomas School bus its the shorty ) The gear box is a D9AC-AA very common gear box. It mounts to the frame with 3 bolts that slide through the frame. There is no adjustment at this point to raise the gear box closer ( the spline ) and yes I know there is a flat spot on the spline with only enters the rag joint one way.

That is not my problem. I was not paying attention when I disconnected the gear box from the truck and once I removed that 12 point bolt from the rag joint the gear box just fell out ( because I had already removed the pitman arm from the center link, the 3 bolts and the power steering hoses ) I am changing out the entire tie rods too.

When I went to reinstall the new gear box there is now a gap yup...1 1/2 inch difference between where the spline on the end of the gear box meets up to the rag joint coupling. I have tried pulling and pushing and even removed the steering wheel. The steering coupling is not a U JOINT type but it seems like something in the steering coupling or shaft has moved? I even tried connecting the steering gear box to the rag joint first and seeing if I could pull down on the entire assembly in order to line up to the frame bolts....no luck....it's still about 1 1/2 inch too short.

Has something moved? Is there a way to lower my steering wheel and disconnecting the shift linkage to regain this 1 1/2 inch difference back? I can attach photos later. I have searched everywhere and I can't seem to find any support for this problem. I know it's the right gear box part. I have even tried putting the old one back in and it still has the same problem.

Thanks guys for your support.

 

[gnathv]

Do you have this diagram? There are a couple of joints that slip together, one of them must have slipped in when you removed steering box.

 

[Skoolie 89]

No I have been searching for a breakdown on the steering column but everything I find is a U JOINT type. Thanks for the diagram. I even ordered a Haynes manual but it doesn't even show the breakdown, it just gives a description.

Thanks

 

[Skoolie 89]

Okay I have resolved the issue in case anyone wants to understand. It was indeed the steering shaft that slide up inside about 1 1/2 inches....I pulled the steering column and right where the rag joint connects to the steering coupling I tapped it with a hammer. There is a keyway that is on the shaft that appears to have a set screw that holds that shaft in place. Apparently my set screw is not holding. So I tapped the shaft and it slide out exactly what I needed it to. I don't think you need to pull the steering column if this happens to you. You can probably tap it from inside the fire wall with a wedge or a block of wood in order to get the shaft to slide back in place. I did loosen the 3 bolts on the inside of the cab at the fire wall so I could line up the shaft with the rag joint....tightened everything up and she is back on the road.