Hey all. Before my camaro goes in for paint I need to reinstall the steering column so the body shop can push it around. I buogh a new box from the internet and check it with my old box and the numbers are the same (5691676). I test fitted the rag joint on my old box and I had to press really hard but I got it started on the shaft. I tried the samething on my new box, which is mouned on the frame, and I cant seem to get it started. I looked at my old Rag and the inside was wiped clean (alot of smooth threads) On the inside of my new Joint there is a step on the flat area, looks like it is a press fit deal. I was wondering if I needed to use the BFH methond on this, also I dont want to scratch up my newly primered firewall so would a piece of wood from inside of the car through the hole help it on the shaft? here is a pic of the step inside the Joint.

http://www.skafia.com/myPix/DCx-541697950.jpg

Here is some information to help you out. First of all, the cast numbers on the gear housing are exactly that, gear casting numbers. The casting was machined at Saginaw Steering Gear and then the specific gears, valves, travel stops, etc were assembled into the machined casting. For a specific period of time, nearly all of the castings were the same part number, but were machined and assembled into hundreds of specific gear assemblies each with their own assembly part numbers.

The original power steering gears (back in the 60s)had a 13/16 diameter input shaft with serrations all the way around. The flexible coupling that attached to that shaft had a flange with serrations that matched, but were only formed for about 1/4 of the diameter. The serrations were usually just on the side where there is the tapped hole for the attaching pinch bolt. This allowed the coupling flange to "wrap" around the gear input shaft when the "pinch" bolt was tightened.

Sometime around 1969 there was a flat added to the gear input shaft. There was a corresponding flat added to the flexible coupling flange. A flange with a flat will NOT assemble to an input shaft with full serrations.

In 1977 the input shaft was reduced from 13/16 to 3/4 diameter with a flat. A new flexible coupling with a 3/4 diameter and a flat was required at that time as well.

So, it sounds as if you have a 13/16 full round serration gear and you are trying to assemble your flexible coupling with a flat to it.

I am not aware of any service flex couplings that are 13/16 diameter with full serrations. You would have to find one in a salvage yard or from one of your classic car shops.

One thing that bothers me is that the gear came from eBay. So I wonder if the person that sold it to you really knew what he was selling.

Good luck,
Jim

Please refer to one of the earlier posting "Steering Gear Box Shaft Smaller." It refers to a flex coupling part number 7806390. This part number flex coupling has a 13/16 flange with a flat. It won't work if you have a full serration input shaft.

the shaft of my box has a flat and so did the old unit.