Steering Box Nightmare!!!

[elks]

Ok not horrible yet, but I got a shake in my steering/front end. While tracking it down I found a lower ball joint loose. While messing with it I could see movement in my steering box. So closer inspection revealed 2 small crack and I think the bolt holes are wallowed out some. I looked and have seen that ORD makes a brace and a plate. Also box itself is leaking a little from the input shaft area. I have never had an issue steering and the system has worked well. I am running 36" tires with cross over set up.

That being said:

1. Is it worth buying a different box? Like a PSC etc? I am happy with what I have but also like the idea of upgrading if possible and that upgrade will give me a noticeable improvement over stock.

2. Is there a guide or write someplace on the complete ORD set up? SOmeone has to have done both the plate and the brace.

3. Will adding the plate just cause a place for rust in the future? I mean from the inside out? I have seen many time where such has occured. How can it be prevented?

 

[AaronJen]

I can't tell you if it's worth it with respect to your question 1., as you are already ahead of me on the steering. I am about to order a crossover setup with the tapped box from ORD (to add hydro assist when I get the $$$). If nothing else, a PSC or similar box sure won't be a downgrade for you.

There are plenty of write-ups on here for the plate and the brace, so just do a search and you'll get pics for both. These two things were the very first changes I made to my '90 when I got it. The brace was easy enough, as you just enlarge one hole in the crossmember and bolt it in. The most annoying part for me was having to cram my huge mitts into the really small spaces to get the bolts back in and tight.

I had the rare "hen's tooth" of a frame that wasn't cracked at the box area, so all I had to do was weld on the plate. You will need to stop-drill the cracks in your frame, grind them out, weld them up, then grind them smooth before welding on the plate.

As for the rust issue, others here would probably be able to tell you the right way to address it, but for me, I just sprayed everything with weld-through primer, welded on the brace, then hit everything with black paint on the outside. There may be other approaches, but for where I live, think what I did was adequate (or so far at least).

Hope this helps some.

 

[ChrisPerry]

http://coloradok5.com/ordframebrace.shtml

 

[elks]

http://coloradok5.com/ordframebrace.shtml

Thanks a bunch anyone else making extra precautions to prevent rusting between the 2 plates? I could see the strength added from the system but would hate to have the 2 plates rust from inside out.