94 F150 steering question

My son has a 94 F150, I-6, 2WD, power steering. On the highway, he has approx 4 inches of play in the steering. We have traced it to the steering box. We have been told to not fool with the adjustments as you can lock up the steering. (We can't anyway, it is rusted solid).

Is it time for a rebuilt box? Or, is this normal?

the steering linkage needs a good check first. pushing on the rod ends won't get it. have an assistant move the steering wheel back and forth enough to move the frt tires an inch (tires on the ground) check linkage for side to side and up and down movement. jack it up and check ball joints and wheel bearings. next look at the i-beam bushings. the bracket for the left side i-beam (right side eng cross member) is worth a look, seen more than one of those ripped almost in two. radius arm bushings worth a look,but an unlikely problem causer.
if all checks good adjusting the hi-point on the box is an option if you can get it broke loose. it's true you can lock it up.it's also true it can be adjusted.
NOTE: Preload (thrust bearing adjustment) and worm-to-rack preload cannot be changed in service. The only adjustment that can be performed is the total overcenter position load to eliminate excessive lash between sector and rack teeth. 1. Disconnect pitman arm from sector shaft. 2. Disconnect fluid return line at reservoir and cap reservoir return line pipe. 3. Place end of return line in a clean container and cycle steering wheel in both directions as required to discharge fluid from gear. 4. Carefully remove airbag assembly from steering wheel hub, then turn steering wheel 45 degrees from right stop. 5. Using an inch pound torque wrench on steering wheel nut, determine torque required to rotate shaft slowly through approximately 1/8 turn from 45 degrees position. 6. Turn steering gear back to center, then determine torque required to rotate shaft back and forth across center position. 7. Adjust if meshload required to rotate shaft back and forth across center position is less than 7 in lb greater than the force required to rotate shaft from 45 degrees to stop. Loosen adjusting nut and turn adjusting screw until reading is 10-14 in lb greater than torque measured 45 degrees from stop. Hold screw in place, then tighten locknut. 8. Check readings, then install pitman arm and steering wheel cover. 9. Connect fluid return line and replenish reservoir.

Thank you for the reply. You have explained the procedure better than the service manual.

We have placed the play in the steering box itself. WHile the truck was running, we saw that the steering wheel was moving, but there was no movement on the sector shaft. We had already checked all the other steering components in preparation for inspection and just general safety. In preparation for adjustment, we tried to loosen the adjusting locknut, but it appears to be rusted solid. We are afraid of breaking it off and so have not done too much more.

I think it's time for a rebuilt box.

Soak it with PB Blaster and let it set overnight it should break loose.

John :)

I have the same problem with my 96 F-150. I believe Ford uses the same ps gearbox from 80 to 96, so it shouldn't be too hard to find one. Let me know if your having trouble locating one. I haven't even started to look yet.

You can find them everywhere for approx $155 to $175. We will start soaking the bolts in PB blaster for a week or so before we work on it. I just got in a set of flare nut wrenches for the PS hose (needed them to do brake line work)and I will probably borrow the arm remover from the place where I buy the box.

I know one place in my area that is cheaper,$100.00 for a rebuilt steering box and last longer same as a new one with a $50.00 core charge if the core is not exchanged on the spot.

Can you give me the name of the place? Do they have a website?

Thank you!

This place is in the Muskegon Mi area.Check around in your area for rebuilt boxes.