Durango power steering gearbox install,with step x step pics - Jeep Wrangler Forum
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Old 08-15-2012, 01:42 PM   #1
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Durango power steering gearbox install,with step x step pics

Thought I'd post a step by step since this question of it being a direct swap always comes up
99 Durango 4wd v8 non snowplow gearbox
First off I had my grill off to do engine work do it made it super easy to reach the gearbox,it can be done with grill on
The old box

Remanufactured box

Looks nearly identical...... But not.we will cover that shortly

Remove the steering shaft bolt completely
13mm and you may have to turn the wheel slightly to make the bolt eaiser to reach,don't worry about realignment because the shafts/pitman arm only go on one position

Remove steering shaft coupling by shaking/tapping and pushing towards cab

Remove the two fluid lines with a 18mm wrench,last time I done this from the bottom it was easier to pull the lines off after the box was unbolted.no need to worry about mixing the lines up as there bent to only fit in one place
Place a bucket underneath to catch your oil
Place the lines high or let them drain

Remove the pitman arm but and lock washer.i used a 24" crescent wrench but I think it's 36mm
Now my arm wasn't tight,I just removed it with a heavy duty puller/heat and lots of beating a year ago.
It's said that some are stuck so tight people just buy a new pitman arm.
If your grill is off you have room to fit a large punch and tap down on the arm

Here's the punch method with 3/4" round bar and can be accessed by removing the plastic swaybar cover

Here's my proto puller/2 jaw

Arm off still connected to the draglink

Old box everything off

Remove the three mounting bolts with a 15mm
These like the pitman arm nut are tight,catch the box it weights about 29lbs

Now if your using the stock bumper the box won't direct fit as claimed
I grinded the stock bumper,notched out for the box to fit and painted

Until the notch is grinded the bolts won't line up

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Old 08-15-2012, 01:45 PM   #2
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See the notch


Now in sure there are other ways to accomplish this,some may grind the box,remove the bumper
Box is in

And looks good

Put on steering shaft coupling on far enough for the bolt to fit in the notch,it only fits one position.the shaft and coupling has a flat spot to line up

Install arm and nut

Like I said everything only fits one position

Check that the connection seals are good

Install in tighten lines but make sure no tube/hose is touching anything,vibration will cause chaffing and bust lines.

Job complete

Refill will proper fluid and leak test

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Old 08-15-2012, 03:39 PM   #3
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You can see here with the grill on and plastic swaybar cover off you can get better view and access of the gearbox
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Old 08-15-2012, 03:46 PM   #4
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Now that looks damn good and nice write up!!!! Bet it is nice having power steering again!!!!
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Old 08-15-2012, 04:36 PM   #5
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Yea no more working out while trail riding

I feel a difference at slow speeds
I feel more turning power,eaiser to turn the steering wheel

Ken
Thankxz for the gearbox
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Old 08-15-2012, 04:43 PM   #6
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Nice write up! I have been looking to doing this sway. Where did you get the box, were you able to get the core exchange for the old one?
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Old 08-15-2012, 04:57 PM   #7
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I bought the gearbox from ken78744 for about half price
New in box
I believe he got it from autozone and exchanged his old one for core

My local parts places would have taken it for core aswell.

Let it be known also that the 99 Durango box only fits a 97-02 wrangler

I'm told the 02-06 requires a different gearbox because Chrysler switched to a different design on the wrangler and Durango.
I read it was a Mercedes gearbox.
I hope someone who knows will chime in.

Also if you aren't running the stock bumper,the swap should be direct,no modifying needed
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Old 08-15-2012, 06:12 PM   #8
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Why the durango gear box? Is it better turn ratio, stronger or just a cheaper alternative vs the TJ box?
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Old 08-15-2012, 07:41 PM   #9
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Originally Posted by rykemc View Post
Why the durango gear box? Is it better turn ratio, stronger or just a cheaper alternative vs the TJ box?
Stronger design
Larger fluid ports internally
So it offers a lil more turning power

Don't remember all the details but I know it doesn't blow seals like the wrangler box does
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Old 08-15-2012, 09:51 PM   #10
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Ur right jeep did switch to the Benz gear box in 03 and I did get the box from Autozone, and a gear box is a gear box parts stores just want the core... So they can send in something to get Remaned.... Don't care on what it is from....
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Old 08-15-2012, 10:31 PM   #11
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hey my box is leaking from the shaft seal. any idea how to replace the seal or I'm gone have to get me a new one? the one i got now is a used one from salvage yard i believe i pay $150 for it. any ideas? my just started liking again!!!!!!! sucks!!
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Old 08-16-2012, 06:46 AM   #12
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Best thing for you to do is take your leaking one off use it as core go to oriellys and pay $179.00 for a new dodge durango steering box and put it on solves all your problems it is a waste of time and money tring to replace seals and bearings in the factory steering boxes for Jeeps...
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Old 08-16-2012, 08:41 AM   #13
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I replaced my seals a year ago
They didn't last long before they leaked again
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Old 08-23-2012, 12:17 PM   #14
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I have the same leak on the steering column side of my steering box on my 99 Wrangler.

Is there a certain year Durango that fits?
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Old 08-23-2012, 12:51 PM   #15
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Quote:
Originally Posted by chilired
I have the same leak on the steering column side of my steering box on my 99 Wrangler.

Is there a certain year Durango that fits?
It is a 98 or 99 durango w360 engine and non snow plow package....
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Old 08-26-2012, 04:00 PM   #16
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How hard/how long does it take to get the front grill off?
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Old 08-26-2012, 06:53 PM   #17
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Quote:
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How hard/how long does it take to get the front grill off?
You can do the swap withoout removing the front grill. Removing the front grill involves removing the radiator too.
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Old 08-26-2012, 07:47 PM   #18
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I removed my grill to do engine work
Wasn't needed for the power steering gearbox

If you do remove the grill it can be done in about an hour providing your bolts aren't rusted solid

Remove bolts,swaybar guard,radiator,a/c cooler,fan,shroud and finally the headlight wires run thru the grill.i imagine the harness could be feed thru.i cut and installed plugs in the middle of my grill for less hassle next time.

Removing the grill was for engine work,not the gearbox change
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Old 05-17-2013, 09:40 AM   #19
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What upgraded box fits an 06?

Thanks,


Flash
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Old 06-14-2013, 06:18 PM   #20
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New gear box in

Hey, so I had the famous pitman bar leak so I decided to do the Durango upgrade and I must say it was not hard at all!

A few tips from the idontthinkuheard garage

1. A second pair of hands is really helpful given the weight of the gear box
2. Get a pitman puller - harbor freight 9.99
3. Buy new hoses dont try to reuse old ones
4. Follow the tutorials they are great!
5. PB Blast s your friend
6. Get a 1 5/16 impact socket, breaker bar and torque wrench - harbor freight

I am sure their is more but this is what I can think of right now.

I did not take the grill off and had no problem getting to everything, though I have a custom bumper so I dont know how different that made the openings.

I ended up buying the durango steering gear box from Napa cost 179.99 minus 111.10 for the core = 68.89.



So thanks again WF for all the help... I love you man!
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Old 06-15-2013, 09:28 AM   #21
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Did anybody else do this swap and not have to notch/grind the bumper. I did mine last year and it fit without any modifications. Just curious.

Oh and mine is leaking again because I went el cheapo and got one from the junk yard. Now I'm contemplating another durango box or just splurging for the Borgeson box


Borgeson 800205 1987-2002 Jeep YJ,TJ,XJ Gear Box - BOR-800205 | PSCMotorsports.com performance steering components, power steering
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Old 07-01-2013, 06:40 AM   #22
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Thanks!

Hey ou812 what a great post both in quality and content. Just what I needed! Actually became a member here just to thank you.
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Old 07-01-2013, 06:42 AM   #23
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Sorry meant to post this here.....I'm a newbie...
Hey ou812 what a great post both in quality and content. Just what I needed! Actually became a member here just to thank you.
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Old 07-01-2013, 06:54 AM   #24
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Very well done, this is such a great and simple step x step it answers so many questions for anyone thinking about this swap (that means everyone with a TJ with bigger than 31"s).

This needs to be made a sticky, great write-up and pics.
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Old 07-01-2013, 12:52 PM   #25
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Subbed for when I get around to doing this. Great write up.

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