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I had my steering box out on this car once already and had a machinist re-do the sector shaft wheel, as the open face ball bearings that counter the side-thrust had disintegrated and there was at least a half revolution of Wheel-play in the steering. The bearings were unavailable and the machinist made up some bushings that initially did the trick but the stock was too soft and I was soon back to a 1/4 wheel of play. I took it back out and sent it to a steering rebuild specialist, who was able to adapt some GM bearings to work and got it back to zero-play, factory specs.

My question is this: both times when I removed it before (and once putting it back in) the only way I could get the box out was to remove the bottom end cap of the box, and, after removing the sector shaft out the top, pull the steering shaft straight out the bottom. Then the steering box could be lifted out easily. Otherwise, I could not get the whole assembly to clear the steering linkage as it slid out of the steering column tube.

The rebuild guy 'strongly recommended' that I find a way to reinstall it without taking it apart as it now has open face ball bearings in it AND is all adjusted to perfection, so I don't want to mess with it.

Has anybody come across this issue before and/or does anyone know the 'trick' to reinstalling the assembly in one piece? I spent almost 3 hours fighting with it today and although I can get it very close to going up between the control arm and the steering linkage, I cannot 'quite' get it. I am now thinking of removing at least one end of the steering linkage as it would drop down about a 1/4" and pivot back almost 2", which might be enough, but I don't want to go to all that trouble if there is an easier way. REALLY HOPING SOMEONE CAN GIVE ME SOME GUIDANCE OR A 'TRICK' TIP!! THANKS IN ADVANCE.

I can't speak to the issue since I have never tried but remember Joe Santana had issues replacing his 40 steering box and column. Maybe his method will work on yours.packardinfo.com/xoops/html/modules/newbb ... ic.php?post_id=67173#forumpost67173

Doesn't one remove the floor plate and pedal pads, disconnect the pedal linkages so they drop down and then remove the gear through the passenger compartment? That is what we did on a 23 series last week, admittedly a different car.

Thanks Howard (Joe) & Ross - appreciate you taking the time to read and post. It would seem the steering link has to be removed. In Joe's thread, it sounds like he 'unthreads' the link by loosening the end clamps and turning the tube out. This will obviously change the wheel alignment and I would sure like to avoid that. I see there are castellated nuts and cotter pins on both ends of the link and my thought was undoing those and separating it that way. Has anybody done that?? Is it feasible? Does one need a ball joint fork?? I am definitely in 'unfamiliar territory' here and don't want to wreck anything; can someone with front-end expertise jump in here?? As always - thanks in advance.