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Durango power steering gearbox install,with step x step pics

45K views 39 replies 25 participants last post by  Furrydogs 
#1 ·
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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#2 ·
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
 
#7 ·
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
 
#12 ·
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...
 
#18 ·
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
 
#20 ·
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 :D

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. :thumb:

http://www.flickr.com/photos/blackmicrophone/9044062653/

So thanks again WF for all the help... I love you man!
 
#21 ·
#24 ·
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.
 
#28 ·
I will add, for recommendation, that this gear box is great!! Especially if you need to upgrade from an old leaky box. Pulling off the pitman arm was a pain in the ass...and lining up the spline since it is reman. box and not perfectly lined up and centered. It would have costed me more to get the stock gearbox actually through Advanced Auto... And to replace the seals would have been just as much work and probably would have ended up busting. Great write up btw!
 
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