Two questions

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miesk5

96 Bronco 5.0
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Yo,

Steering Box Frame Crack Repair

Source: by Ford

http://www.supermotors.net/getfile/520094/fullsize/steeringcrack.jpg

The following areas of the frame should be checked before performing a steering gear frame liner repair: the frame rail near the steering gear top and bottom flanges, and the frame rail at the steering gear bolt heads. If there are cracks in these areas of the frame, the frame must be replaced. Inspect the mounting surface of the steering gear for signs of motion, loose rivets or cracks. Removal of the steering gear may be necessary to check for cracks in the frame liner. If the frame liner is cracked or has loose rivets, repair the liner by using Frame Repair Kit E6TZ-5K130-A. If necessary a steering gear liner to frame, rivet repair can be made by using the procedures described in the illustration.

Rivet Removal and Replacement

1. Drill a 1/8-inch hole through rivet.

2. Redrill the hole through the shank of the rivet with an 11/32-inch drill.

3. Use an air chisel to remove rivet head.

4. Drive out rivet with a punch or other suitable tool.

5. Line drill one 7/16-inch hole marked "V" to 9/16-inch diameter.

6. Install one 9/16-inch bolt in the direction shown in the first illustration.

7. Position bolt head on top (next to crossmember) with hex head flat to the rear to provide best clamping.

8. Install one 9/16-inch washer nut side only and one 9/16-inch nut. Tighten to 190 N-m (140 ft-lb).

NOTE: Tack weld the nut to the bolt as shown in the second illustration..."

Gear box loose on frame.

Action(s) to Take:

* Check bolts for damage and replace as required. If bolts are not damaged, tighten mounting bolts (3) to 68-84 N-m (50-62 ft-lb).

...

Ford did not provide braces for our Broncos.

Ford did provide info for 96 F350 though;

"Steering Gear Frame Liner Service, F-350

Cracks may appear in the frame (5005) at the frame side rail (5015) near the steering gear (3504) or steering gear bolt heads, or in the steering gear frame liner. "

...

Gacknar proposed elsewhere, "From the steering box neck to the upper most drop bracket bolt in the crossmember. Not nearly as steep of an angle as the Jeep brace. There is about a 1" drop from the steering box to the bolt in the crosmember and the bar would agle back about 2" to meet the crossmember. If I used rod ends and a strap at the steering box would this increase the strength under compresion?"

Here is the crack in his 86;

http://www.supermotors.net/getfile/498311/fullsize/crack-1.jpg

Gacknar did build & installed the bar.

"1/4" angle bolted on with the two bolts you see facing you for the pass side (Drivers side beam) drop bracket, with a gusset welded in it between the bolts. The plate that is clamped to the box is also 3/8", the tube is just something my neighbor had laying around.

Please note, the steering stabilizers have been removed for fabrication, but will be reinstalled later. Thats what the brackets are with nothing on them.

This is from the ground looking up. Are you seeing the triangle?

http://www.supermotors.net/getfile/919577/fullsize/dsc06241.jpg

It works.

With A broken weld, and a lower rivet looser than a slinky, ALL the forward frame horn flex is gone.

The bad news

There is still a very slight amount of flex at the crosmember behind the steering box. I believe this is due to the small U-bolt I am using. I am going to get a more robust U-bolt.

While a crossmember in front of the steering box would not hurt, It may not be enough to stop the lower forward rivet from coming loose. The truck I had posted in post #32 had a tube welded from frame horn to frame horn when it was repaired the third time. It still tore itself apart again because they never fixed the actual cause, a loose crossmember rivet. But that's on a truck that already had the problem, and was being repaired by people who did not understand what the cause of the failure was.

The forward lower driver side crossmember rivet was loose.

I am going to try again to see if I can replace the rivet with a bolt. For some reason I had it in my head that you could not do it without removing the spring bucket, but the TSB Steve posted does not mention removing it and makes it look like you can replace it fairly easily.

http://www.supermotors.net/registry/2742/54113-2

http://www.supermotors.net/registry/media/520094_1

Replaced the loose rivet with a 9/16" bolt per the TSB from Ford.

Between that and the brace there is no movement, of any kind, anywhere.

So, getting the rivet out was a total pain in the but! Grinding the head off was easy, but it just would not knock out. I ended up having to drill three increasingly larger holes all the way through it before it finally knocked out.

Next step was to drill out the hole to 9/16ths"

(Took me a half day to find a drill bit that size)

Next you have to finagle the bolt in from the closed off side of the frame. I ended up pulling it through with a piece of fishing line and working it into a vertical position with a ***** driver, then lightly tapping the head until enough of it was through the hole to pull it through.

Then, if you get everything just right you can just barely get a box end wrench in there to hold the head of the 9/16" bolt wile you tighten the nut down to 140ft/lb. Tada! You have replaced your loose rivet with a 9/16" bolt per Fords TSB.

http://www.supermotors.net/getfile/923478/fullsize/dsc06314.jpg

http://www.supermotors.net/getfile/923475/fullsize/dsc06310.jpg

http://www.supermotors.net/getfile/923477/fullsize/dsc06312.jpg

See more pics @ http://www.supermotors.net/clubs/superford/registry/4103/55989-4

If it opens.

...

Jopes had a 78 and wrote, "hard to see mine. but it goes from the coil tower past the front of the ps box. 3/8" plate. welded all the way around. my frame ripped as well."

http://www.1ton4x4.com/steering/DCP_6921.JPG

...

Here is a Dodge brace:

http://www.lilreddad.com/uploads/steering_brkt_montgomery_1.jpg

..

Some owners have reported same cracks in their Broncos from 1978 through 1996.

GKR did this in his 96 Bronco;

http://www.supermotors.net/getfile/428563/fullsize/dscn1339.jpg

http://www.supermotors.net/getfile/428563/fullsize/dscn1339.jpg

http://www.supermotors.net/getfile/428564/fullsize/dscn1340.jpg

"I just formed a strap with a really tight fit around the steering box and the flat channel meets with the flat spot on the box. Couldn't think of another way to grab ahold of the box."

I believe some Jeeps were retro-fitted with brace bar, but they had a front cross member to attach one end of the bar.

 

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