94 E150 steering box to flex connector
 

I just pulled of my steering gear box for a rebuild as the pitman seal was leaking a quart every few days. Everything went smooth but now I can't get the input shaft on the box to connect to the clamp on the U-joint on the steering shaft (intermediate shaft??). It is toed with a flat spot both on the inside of the clamp and the outside of the shaft. I managed to get it in with the help of a friend, but think its only halfway in. I got one bolt through the frame into the gear box. The other 2 bolts will not line up though, most likeley because the shaft from the gear box is not all the way inserted in the clamp on the u joint. I remember it being alot more difficult to pull off then when it went on. I am sure it has to go on further. Any tips to pressing the input shaft on the gearbox back into place on the steering shaft? I tried tapping it with a hammer but didn't want to hit it too hard. Anything I'm missing? Please help, I need to see how good of a job I did on the rebuild!!!! All tips appreciated!!!!!

RE: 94 E150 steering box to flex connector
 

Did you try spreading the gap 'slightly' on the connector/hub?

RE: 94 E150 steering box to flex connector
 

a little bit. That must be the only trick huh? I was going to hammer a chisel or flathead into the gap but there is nowhere to swing a hammer. I guess I'll have to try harder. Or maybe press it in with c-clamps? any more suggestions?

RE: 94 E150 steering box to flex connector
 

Put some anti seize on the splines of gear box. Also make yourself a mark with white out on the coupler and splines to indicate where your keyed spline is for easier line up.

RE: 94 E150 steering box to flex connector
 

Ok, I got it. I drove a flathead in a little bit and spray a ton of PB blaster. It almost fell in place:). I am having a problem with the box now though. Check new thread.