MIDNIGHT RIDER
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- Sep 29, 2005
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Yesterday broke a heat record that had been standing since 1936.
The radio announcer warned of the dangers of being outside and recommended anyone without A/C to spend the day in the library or the mall (the nearest mall is a good fifty-miles away).
Myself, I opted for the cool shady spot underneath my truck out in the gravel driveway.
Once I had a decent pitman-arm puller in hand, plus a proper 1-5/16 socket to remove/install the pitman-arm nut --- 170-230 ft-lbs according to my genuine Ford service manual --- , the task went fairly well.
On my 1985 F-350, the three mounting bolts are 7/16-14, 5-3/8 long, threaded for two inches, with an un-threaded 1/8-long pilot, 5/8 head, 54-66 ft-lbs.
Only a 1/2-inch shoulder and the threaded area are 7/16, with the rest of the shank being app. 13/32; I imagine so that any built-up crud might still pass through the bushings in the frame-rails.
The Borgeson shaft being siezed and not telescoping gave me more fits than any other part of this project.
I finally had to completely remove the Borgeson, drive the inner shaft out with a long punch, clean the inside of the outer shaft shotgun barrel style, and hand-file the inner shaft until it was once again a sliding fit.
Plenty of anti-sieze was used on the Borgeson and every bolt and spline of the steering-box.
The pressure line requires 1/2-inch line-wrench; the return line requires a 5/8 flare-line crow's-foot.
I pulled the Pitman-arm while the box was still mounted and just let it hang by the drag-link/tie-rod.
Seeing as my truck has a 2-inch body-lift, with the left tire out of the way, I was able to pull loose a rubber skirt held in place by plastic barbed rivets, and easily access the hydraulic lines and shaft coupling from the wheel-well by reaching through the area between the frame and wheel-well.
One bit of advice that I failed to heed at first and required me removing the new gear-box and starting over; RUN A TAP THROUGH THE BOLT-HOLES.
Although better than factory-new, these RedHead gear-boxes are built from old used units of un-known heritage.
After I got the HEAVY box lined up and held in place by the two bottom bolts, the top bolt would not screw in no matter what I tried.
I took it back down, layed it on the bench, and ran a thread-tap through that top bolt-hole.
The threads well terribly stripped and crossed (some
idiot with an air-gun, no doubt); REDHEAD should have caught this. 
I managed to salvage about 1/3 of the threads; and, if it hadn't of meant my entire endeavors of the day being a complete waste, plus having to box up and expensively return that heavy unit, I would have taken it straight back for a replacement.
As it is, if it ever causes a problem, I will attempt to re-drill/re-thread to 1/2-13
Considering the condition of that top hole, I only torqued it to the minimum 54-ft-lbs; the other two got the maximum 66-ft-lbs.
It is now mounted, bled, and ready to roll, but I haven't yet driven it; I was just too nasty and grimy to be in the cab, making a greasy mess of my nice captain's chairs.
The radio announcer warned of the dangers of being outside and recommended anyone without A/C to spend the day in the library or the mall (the nearest mall is a good fifty-miles away).
Myself, I opted for the cool shady spot underneath my truck out in the gravel driveway.
Once I had a decent pitman-arm puller in hand, plus a proper 1-5/16 socket to remove/install the pitman-arm nut --- 170-230 ft-lbs according to my genuine Ford service manual --- , the task went fairly well.
On my 1985 F-350, the three mounting bolts are 7/16-14, 5-3/8 long, threaded for two inches, with an un-threaded 1/8-long pilot, 5/8 head, 54-66 ft-lbs.
Only a 1/2-inch shoulder and the threaded area are 7/16, with the rest of the shank being app. 13/32; I imagine so that any built-up crud might still pass through the bushings in the frame-rails.
The Borgeson shaft being siezed and not telescoping gave me more fits than any other part of this project.
I finally had to completely remove the Borgeson, drive the inner shaft out with a long punch, clean the inside of the outer shaft shotgun barrel style, and hand-file the inner shaft until it was once again a sliding fit.
Plenty of anti-sieze was used on the Borgeson and every bolt and spline of the steering-box.
The pressure line requires 1/2-inch line-wrench; the return line requires a 5/8 flare-line crow's-foot.
I pulled the Pitman-arm while the box was still mounted and just let it hang by the drag-link/tie-rod.
Seeing as my truck has a 2-inch body-lift, with the left tire out of the way, I was able to pull loose a rubber skirt held in place by plastic barbed rivets, and easily access the hydraulic lines and shaft coupling from the wheel-well by reaching through the area between the frame and wheel-well.
One bit of advice that I failed to heed at first and required me removing the new gear-box and starting over; RUN A TAP THROUGH THE BOLT-HOLES.
Although better than factory-new, these RedHead gear-boxes are built from old used units of un-known heritage.
After I got the HEAVY box lined up and held in place by the two bottom bolts, the top bolt would not screw in no matter what I tried.
I took it back down, layed it on the bench, and ran a thread-tap through that top bolt-hole.
The threads well terribly stripped and crossed (some
idiot with an air-gun, no doubt); REDHEAD should have caught this. I managed to salvage about 1/3 of the threads; and, if it hadn't of meant my entire endeavors of the day being a complete waste, plus having to box up and expensively return that heavy unit, I would have taken it straight back for a replacement.
As it is, if it ever causes a problem, I will attempt to re-drill/re-thread to 1/2-13
Considering the condition of that top hole, I only torqued it to the minimum 54-ft-lbs; the other two got the maximum 66-ft-lbs.
It is now mounted, bled, and ready to roll, but I haven't yet driven it; I was just too nasty and grimy to be in the cab, making a greasy mess of my nice captain's chairs.
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