MoparGuy68
Well-Known Member
I began the process of swapping out my PS Gearbox this past Saturday. I am making a thread in the Bergman section because I got all the components from him, except for the cooler. I got the cooler from Perma-Cool in CA.
Sun Feb 2nd:
Came up with a plan to custom mount the cooler to the radiator support. Bought the items needed to mount the cooler at Ace Hardware. Fabricated an upper bracket extension from a strip of aluminum. Mounted the cooler.
Sat Feb 8th:
1. Removed battery and tray
2. Completely drained the coolant from radiator. 1.5 gallons came out..
3. Loosened all 4 spark plugs
4. Loosened all 6 header flanger bolts (2 of them did NOT want to come out)
5. Loosened 3 header collector bolts and nuts
6. Lowered steering column so steering wheel rests on the seat
7. Detached steering column from the coupler (this was tough!!)
8. Pulled steering column out of coupler
9. Disconnected high pressure and return lines from gearbox and pump
10. Drained ATF fluid out of the pump reservoir
11. Removed the old pump from engine
First barrier was removing the middle two header flange bolts. They didn't want to budge. I had to heat them both with a torch multiple times, over and over and over.. The 6th and final bolt being the most difficult to break loose. And that one had a header pipe running directly in front of it, so no socket could be used, only my box end wrench.
Second barrier was getting the pin out of the coupler that prevents the column from being pulled out of the coupler. I read online that you should be able to pound it out with a punch and hammer. That did NOT work for me. The pin wouldn't budge. I had to drill it out with a 20V drill. The first drill bit I used got stuck inside the pin and coupler! It was too small in diameter, and went to deep. That one was supposed to be making a pilot hole. Had to remove it with pliers. No key chuck on these new drills, so the keyless chuck wouldn't grip it tight enough to back it out. Successive use of larger bits, ultimately disintegrated the pin and I was able to pull the column out of the coupler!
That's all I've accomplished so far.
To proceed, I need suggestions on how to remove the coupler from the steering box input sector shaft. There is NO roll pin holding it to the shaft, the hole for the roll pin is empty. Even with no roll pin, I cannot get it to budge. It doesn't want to come off the shaft. I need some kind of a puller tool to pull it off. I want to remove it to allow more room to get the box out of the car.
Sun Feb 2nd:
Came up with a plan to custom mount the cooler to the radiator support. Bought the items needed to mount the cooler at Ace Hardware. Fabricated an upper bracket extension from a strip of aluminum. Mounted the cooler.
Sat Feb 8th:
1. Removed battery and tray
2. Completely drained the coolant from radiator. 1.5 gallons came out..
3. Loosened all 4 spark plugs
4. Loosened all 6 header flanger bolts (2 of them did NOT want to come out)
5. Loosened 3 header collector bolts and nuts
6. Lowered steering column so steering wheel rests on the seat
7. Detached steering column from the coupler (this was tough!!)
8. Pulled steering column out of coupler
9. Disconnected high pressure and return lines from gearbox and pump
10. Drained ATF fluid out of the pump reservoir
11. Removed the old pump from engine
First barrier was removing the middle two header flange bolts. They didn't want to budge. I had to heat them both with a torch multiple times, over and over and over.. The 6th and final bolt being the most difficult to break loose. And that one had a header pipe running directly in front of it, so no socket could be used, only my box end wrench.
Second barrier was getting the pin out of the coupler that prevents the column from being pulled out of the coupler. I read online that you should be able to pound it out with a punch and hammer. That did NOT work for me. The pin wouldn't budge. I had to drill it out with a 20V drill. The first drill bit I used got stuck inside the pin and coupler! It was too small in diameter, and went to deep. That one was supposed to be making a pilot hole. Had to remove it with pliers. No key chuck on these new drills, so the keyless chuck wouldn't grip it tight enough to back it out. Successive use of larger bits, ultimately disintegrated the pin and I was able to pull the column out of the coupler!
That's all I've accomplished so far.
To proceed, I need suggestions on how to remove the coupler from the steering box input sector shaft. There is NO roll pin holding it to the shaft, the hole for the roll pin is empty. Even with no roll pin, I cannot get it to budge. It doesn't want to come off the shaft. I need some kind of a puller tool to pull it off. I want to remove it to allow more room to get the box out of the car.