Power Steering Gear Box

Remove and replace the power steering gear box on a 1970 AMC Rebel Machine, including disconnection of steering linkage and hydraulic lines.

Warnings

Tools required

Parts

• Power steering gear box × 1 — Use OEM specification or quality aftermarket equivalent
• Power steering gear box mounting gasket or seal × 1 — Check if included with gear box
• Hydraulic line crush washers × 2 — Use OEM specification

Fluids

• Power steering fluid (Type A or Dexron automatic transmission fluid) — 2 qt

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks behind rear wheels
3. Disconnect negative battery cable to prevent accidental starter engagement
4. Raise front of vehicle and support securely on jack stands at frame rails
5. Remove front wheels to improve access if needed
6. Mark relationship of pitman arm to sector shaft for proper reassembly alignment
7. Apply penetrating oil to all fasteners that will be removed and allow to soak for 15-30 minutes

Procedure

1. 1

   Drain and disconnect hydraulic lines
   Position drain pan beneath steering gear box. Using flare nut wrenches to prevent rounding, loosen and remove the pressure line fitting from the gear box input port (typically on passenger side). Allow fluid to drain completely. Remove return line from output port. Cap or plug open ports on gear box and lines to prevent contamination and further fluid loss. Note the routing of lines for proper reinstallation.
2. 2

   Disconnect steering column coupling
   Working from inside the engine compartment, locate the flexible coupling or rag joint connecting the steering column shaft to the gear box input shaft. Remove the pinch bolt(s) securing the coupling to the gear box input shaft. Mark the relationship between the coupling and shaft if not already marked. Separate the coupling from the gear box shaft by sliding it up the steering column shaft.
   ⚠Do not allow the steering wheel to rotate once disconnected, as this can damage the horn contact ring and potentially affect centering.
3. 3

   Remove pitman arm from sector shaft
   Remove the castle nut or lock nut securing the pitman arm to the sector shaft of the steering gear box. The sector shaft typically has a splined or tapered connection. Install a pitman arm puller according to the tool manufacturer's instructions, ensuring the puller is properly seated and centered. Tighten the puller to apply even pressure until the pitman arm releases from the sector shaft. Remove the puller and pitman arm.
   ⚠️Never strike the pitman arm or gear box with a hammer. This can damage internal components and create steering system failure.
4. 4

   Remove gear box mounting bolts
   Locate the three mounting bolts securing the steering gear box to the frame rail (typically on driver side). These bolts pass through the gear box mounting flange and thread into the frame. Support the gear box with one hand or have an assistant support it. Remove the mounting bolts completely using a socket and ratchet or wrench. Note the length and position of each bolt if they differ.
5. 5

   Remove steering gear box from vehicle
   With all connections and mounting bolts removed, carefully maneuver the steering gear box away from the frame mounting surface. Rotate and angle the gear box as needed to clear the sector shaft through the frame opening and navigate around exhaust components or other obstructions. Lower the gear box from the vehicle. Place on a clean work surface for inspection.
6. 6

   Prepare new gear box for installation
   Unpack the new steering gear box and verify it matches the original unit in mounting configuration and port locations. Remove all shipping plugs from hydraulic ports. Check that the sector shaft is centered in its travel range by rotating it fully lock-to-lock and returning it to the middle position. Install new mounting gasket or seal on the gear box mounting flange if applicable. Apply thread sealant tape to hydraulic fitting threads according to manufacturer specifications.
7. 7

   Install new gear box into vehicle
   Maneuver the new steering gear box into position, guiding the sector shaft through the frame opening. Align the mounting flange with the frame mounting surface. Start all three mounting bolts by hand to ensure proper thread engagement before tightening any fully. Once all bolts are started, tighten them progressively in a cross pattern to draw the gear box evenly to the frame. Tighten mounting bolts to manufacturer specification (typically 60-80 ft-lbs for AMC applications, verify with service manual).
8. 8

   Reinstall pitman arm
   Clean the sector shaft splines and pitman arm bore with a wire brush to remove any corrosion or debris. Align the pitman arm with the sector shaft using the alignment marks made during disassembly. Slide the pitman arm onto the sector shaft, ensuring proper spline engagement. Install the castle nut or lock nut and tighten to manufacturer specification (typically 150-185 ft-lbs for this application). Install cotter pin if equipped with castle nut.
9. 9

   Reconnect steering column coupling
   Align the flexible coupling on the steering column shaft with the input shaft of the new gear box, matching the alignment marks made during disassembly. Ensure the coupling slides fully onto the gear box input shaft. Install the pinch bolt and tighten securely (typically 20-30 ft-lbs). Verify that the coupling has adequate clearance and does not bind through full steering travel.
10. 10

    Reconnect hydraulic lines
    Remove plugs from hydraulic ports on the gear box. Install new crush washers on line fittings if equipped. Connect the pressure line to the input port (typically marked 'P' or on passenger side) and the return line to the output port. Using flare nut wrenches, tighten fittings snugly but do not over-tighten (typically 20-25 ft-lbs). Verify lines are routed correctly and will not contact exhaust or moving components.
11. 11

    Fill and bleed power steering system
    Reinstall front wheels if removed and lower vehicle to ground. Locate the power steering pump reservoir and fill with appropriate power steering fluid to the cold fill line. Start the engine and allow to idle. Turn the steering wheel slowly from lock to lock several times without holding at full lock. Check fluid level and add as needed. Repeat this process until fluid level stabilizes and no air bubbles are visible in the reservoir. Check all connections for leaks.
    ⚠Do not hold steering at full lock for more than 2-3 seconds as this creates excessive pressure and heat in the system.

Reassembly

1. Reconnect negative battery cable
2. Top off power steering fluid to proper level after system has been operated
3. Check for any fluid leaks at gear box connections and fittings
4. Verify all mounting bolts are properly torqued

Verification

• Start engine and verify no unusual noises from steering system
• Check for fluid leaks at all hydraulic connections with engine running
• Test steering operation by turning wheel lock-to-lock while stationary - should be smooth with no binding
• Perform a careful test drive at low speed in a safe area to verify proper steering response and returnability
• After test drive, recheck fluid level and inspect all connections for leaks
• Verify steering wheel is centered when driving straight ahead - if not, front end alignment may be required

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