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So, I read everything I could find on rebuilding the steering box. I drove out the old bushings, no problem there. I read a tip that said to freeze the new bushings before installing them to make it easier to drive them in. I also squirted the bore of the steering box with WD-40 to give it some lubrication. I also obtained the correct bushing driver so I would not distort them on installation.

When I drove in the inner bushing after a couple taps it fell right through the box! I can easily move it with finger pressure. I then installed the upper bushing. It went in fine, but now the sector shaft won't clear the bushing. The bushings were Omix ADA items made in taiwan. I'm guessing I'm going to need to buy some made in the USA bushings and try again. Any other ideas?

One more question. Does anyone know a source for made in the USA inner and outer bearing? Thanks.

You need to get a reamer and ream the bushings to fit the sector shaft....

Harbor Freight sells a set....

If your bushing OD is too small,You can chuck up the bushing in a lathe and lightly hit it with a knurling tool to increase the OD
This cheat will not work on heat treated materials, hardened races, or anything harder than tool steel

I boutht the busshings from walcks, i did replace them with the steeringbox still in the jeep, no problems, no reaming everything fits fine with no playing anymore...
I put the bushings a few days before in the freezer .

Erik

This is going to be my next project after the rally next month - luckily I have a spare box to rebuild. I just have to figure out how to get the steering wheel off! I already have all the parts that I bought from Rapco (I think - or maybe it was Midwest Military). I am a firm believer of NOT buying OMIX ADA - I've been burnt too many times (wasted over $1,000 and many hours of work). I always ask before I buy. Walcks and Kaiser Willys sell many import parts, but they will be honest with you about them - go ahead and spend the few extra dollars and save in the long run!