In-truck replacement of Power Steering Output shaft seal

[JohnnyPopper]

Has anyone tried to replace this seal in-truck?

Looks feasible, but thought I would tap the brain trust before diving in.

TIA for your assistance!

[Mike81K10]

Are you talking about the one on the firewall? Have the seal and the two piece metal plates.

[JohnnyPopper]

No, the actual shaft the pitman arm is bolted to.

The kit came with two seals, a flat washer, and snap ring.

[VileZambonie]

You mean the steering gear box. Usually when the seals start leaking there is play in the gearbox. With the wheels on the ground, have an assistant rock the steering wheel while you watch the sector shaft for play. If play exists, changing the seal will be a waste of time. Consider a reman unit if it is walloped. If it looks okay, remove the pitman arm, snap ring and have at it. Try not to scratch the shaft when doing it.

[JohnnyPopper]

I guess you're right, it really doesn't output anything 

Thanks VZ, I'll do just that!

[MIKE S]

It can be done. The best way after removing the pitman arm is to center the steering wheel and remove the four bolts on top that hold the pitman shaft cap to the housing. Tap the sector shaft gently from the bottom and pull the cap and shaft from the top. Do not disturb the adjustment nut on the top. You will need the repair kit that has the metal plate gasket for this type of repair. You will not loose any of the internal balls as long as you don’t turn the steering wheel after removal. You can also try the messy way by pulling the pitman arm then snap ring then start truck and tun steering wheel to the lock and use the internal pressure to “blow” the seal’s out. It doesn’t always work but you won’t know if you don’t try.

[JohnnyPopper]

Thanks Mike, never thought of 'blowing out' the seal.

I thought I would drill some small holes in the seal and use a slide hammer, like pulling out a dent.

[MIKE S]

Make sure you wrap the splines with masking tape one wrap before installing seal.

[JohnnyPopper]

Ok, but what's the theory behind that?

[MIKE S]

Not to cut the seals while slipping them up the shaft into the housing. Those splines are sharp.

[JohnnyPopper]

Ah...Good catch!

Thanks Mike!

[JohnnyPopper]

Success! No wallop in the shaft so I dove in.

Couldn't pick the seals, so went Johnnpopper.

Drilled 1/16 hole in each seal, screwed in a fine thread drywall screw and pried out with dikes against the casing.

Blew out hole with brake cleaner.

Gently tapped the new ones in, using washer as surface so as not to dent the seal.

Tapped till they bottomed, inserted snap ring but too far into the casing.

Got it all cleaned up, parked, only to see oil dripping. Thought it must be residual, but NO, the snap ring, washer were sitting on the pitman arm and seal was starting to come out.

ROOKIE MISTAKE! Oh well, made sure it was correct the second time...