tdavis
05-23-2005, 09:40 PM
After several times of taking apart my FJ60 power steering box, including letting loose all the little balls..
I have figured out the 5 minute, get all the balls back into the piston/screw with little or no grease method.
Yes, it's possible.
First, I have to apologize - I was going to use the same pic several times, with arrows pointing to what I am talking about, and then I realized I'm a lousy artist.
Second, I am using an FJ60 box - so everything is *reversed* from the IFS box.
Last, I'll probably screw this up trying to describe it..
This is the completed assembly, except it's missing two screws and the strap holding the tube in place.
http://www.pirate4x4.com/forum/attachment.php?attachmentid=189011&stc=1
Here's how to do it:
1) On the piston, remove the two screws, the strap, and the split tube.
2) Place the piston back on the input shaft/valve body.
3) In the hole farthest away from the pressure fittings/valve body, near the front of the piston, place one ball.
4) Using a small screwdriver, place the tip of the screwdriver on the ball, keeping it from coming out.
5) Now slowly, gently turn the input shaft. The ball will disappear down into the piston/screw assembly. If the piston starts to move away from the valve body, gently turn the input shaft and bring it back. You may have to leave the screwdriver blocking the hole to stop the balls from coming out. You shouldn't have to use more than a 1/4 turn to make the ball go in.
6) Repeat until a ball shows up in the other hole. You must STOP at this point. Do NOT turn the assembly any more, you can cause a ball to go past the holes into the rest of the piston body.
7) Take the split tube, and pack one half with grease. Now, fill it with balls. No, don't be silly, just leave it split and fill it that way - once loaded with balls, place the two halfs back together.
8) All balls should now be either in the tube, or in the two holes. The balls in the holes may be kinda loose.
9) Place the split tube back into the holes, with the balls. Once you've done this right, you'll be able to turn the input shaft, and the piston will want to move. DO NOT MOVE THE PISTON MORE THAN 1/2", or turn the input shaft more than 2 full turns! You will also note that the input shaft will no longer turn when you have the piston tight against the valve body.
10) Replace the strap and two screws holding the split tube.
11) Place assembly back into box, and look for any extra balls laying around.
I've found this works great - no major grease, no fighting with it.
I have figured out the 5 minute, get all the balls back into the piston/screw with little or no grease method.
Yes, it's possible.
First, I have to apologize - I was going to use the same pic several times, with arrows pointing to what I am talking about, and then I realized I'm a lousy artist.
Second, I am using an FJ60 box - so everything is *reversed* from the IFS box.
Last, I'll probably screw this up trying to describe it..
This is the completed assembly, except it's missing two screws and the strap holding the tube in place.
http://www.pirate4x4.com/forum/attachment.php?attachmentid=189011&stc=1
Here's how to do it:
1) On the piston, remove the two screws, the strap, and the split tube.
2) Place the piston back on the input shaft/valve body.
3) In the hole farthest away from the pressure fittings/valve body, near the front of the piston, place one ball.
4) Using a small screwdriver, place the tip of the screwdriver on the ball, keeping it from coming out.
5) Now slowly, gently turn the input shaft. The ball will disappear down into the piston/screw assembly. If the piston starts to move away from the valve body, gently turn the input shaft and bring it back. You may have to leave the screwdriver blocking the hole to stop the balls from coming out. You shouldn't have to use more than a 1/4 turn to make the ball go in.
6) Repeat until a ball shows up in the other hole. You must STOP at this point. Do NOT turn the assembly any more, you can cause a ball to go past the holes into the rest of the piston body.
7) Take the split tube, and pack one half with grease. Now, fill it with balls. No, don't be silly, just leave it split and fill it that way - once loaded with balls, place the two halfs back together.
8) All balls should now be either in the tube, or in the two holes. The balls in the holes may be kinda loose.
9) Place the split tube back into the holes, with the balls. Once you've done this right, you'll be able to turn the input shaft, and the piston will want to move. DO NOT MOVE THE PISTON MORE THAN 1/2", or turn the input shaft more than 2 full turns! You will also note that the input shaft will no longer turn when you have the piston tight against the valve body.
10) Replace the strap and two screws holding the split tube.
11) Place assembly back into box, and look for any extra balls laying around.
I've found this works great - no major grease, no fighting with it.