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I know the box is smaller and sector shaft is different, but are the worm gear bearings interchangeable between cj's with the smaller Ross Steering Box?

You are treading on thin ice here. You can only be sure what will interchange if you are sure what assembly number steering gear you are looking at. The box casting number is not the assembly number so unless you have the original ink stamping on the box or a reman tag you can only guess which of the many boxes that use that casting number have for a bearing part number.

Have you not checked with Midwest Military for the M38A1 gear box parts?

I replaced my sector shaft and bushings and found the plastic cage that holds the ball bearings underneath the worm gear to be broke up/worn out and was actually missing two of the balls. I have one that looks identical but its out of a cj3A. Haven't bought anything from Midwest, just was looking to put it back together tonight, maybe I will wait and call them.

think I answered my question, From Midwest Military:

Jeep Steering Gear Worm Bearing Kit
Currently available bearing kits were not made properly and don't fit.
These accurately-produced worm gear bearings will now allow you to
properly rebuild your gear box, and tighten up your steering.
Correct for all jeeps, Civilian and Military.
$26.00


what's the best way to figure out how many shims to use?

Are you using the Ross service manual in our downloads section?

http://www.willysmjeeps.com/v2/modules. ... it&lid=136

and TM 9-8015-2 Chapter 12 Steering Gear Rebuild?

http://www.willysmjeeps.com/v2/modules. ... it&lid=140

I am now, thanks!!!