Well, nothing lasts forever- so I can't bitch about a 25 year old seal (2000, 2500)
I'm sure it's a pain in the ***. The gearbox itself is quiet so no reason to suspect anything else is amiss, and the shaft seal is readily available.

Edit:
The more I look at this, perhaps I should just replace the gearbox? Rock Auto has a BBB new (not reman) for a little over four bills, and it looks mostly plug and play to replace rather than messing with seals.
Anyone used this one before?
https://www.rockauto.com/en/moreinfo...=7416&jsn=2538

 

Reman'd steering boxes are quite a crapshoot. I've had good luck replacing the seal and it's fairly easy. Hardest part is removing the pitman arm after removing the 1-5/16" bolt. Once the seal is replaced, make sure that the steering box adjustment is performed to take the slop off the output shaft, so that the seal doesn't fail prematurely. There should be several YouTube videos that show the process.

 

He says input, not sector shaft. So no need to pull the pitman I'd think?

I've never attempted this seal. If you do it OP, please post up. If your box is working well, KEEP IT!

 

A NEW box for four bills??? Link please.

 

Bottom of my post.
They have 6 new boxes listed- but only the one I have listed fits the quad cab I have. No clue as to why this matters, but apparently it does...

After reviewing the service manuals (I have '98 and '01, both mostly the same) I've determined that preload adjustments for the worm bearing and pitman shaft are above my pay grade. Besides, if I'm going to pull the box for the shaft seal- it would be stupid not to do the pitman arm as well. I'll spend at least as much for labor putting it in the shop for seal replacements- and still have a 25 year old box- as I would buying the new one and just bolting it in myself.

The BBB (aka Genco, Vision-OE, Wilson) is listed as NEW (as opposed to remanufactured), but WTF does that really mean? I too, am skeptical of a completely new box for just over four bills- but I'm often surprised at the cheap prices-sometimes at decent quality- that comes out of China.

So the consensus here is I'd still be better off paying a shop (I'm going to call, but I'm thinking the same ballpark cost as the new box) to throw new seals in it instead?

 

I did some searching and they say "power steering gears are 100% new, to prevent unidentified deterioration." It's about time!!! I looked up a 96 and they have them also. Brands i never heard of but can't be any worse than getting used/worn ones in a reman you have to send back.

 

Hard to screw up a steering box.... and "new" means NO worn parts inside..... If you are going to crank out the bucks to have a shop go thru it, I think I would MUCH prefer swapping it for a new box myself, and calling it a day.

 

I believe BBB offers the O'Reilly remans, which are horrible.

I understand we're talking "new", but good luck. I'd be interested to hear results-- and more importantly, long term results.

Anyone who works in the auto repair industry knows that today more than ever used OEM is usually preferable to new China/ring-of-fire

NOW, these boxes were problematic so if OP had complaints with existing box I'd say new couldn't be worse, but if the existing box is solid, PLEASE at least don't scrap it just due to leaking seals. I might pay shipping to get it to me.

Quad Cab only matters because the ratios changed a bit for longer wb. You can actually go back and forth if you'd prefer quicker or slower steering.

Finally, you might check Cancraft in BC. They seem to actually know what they're doing. Last time it was $500 for me, but prices may have increased. Id rather have a used box gone through by a skilled rebuilder who knows what they're doing (read: not Redhead) than new China slapped together by slave labor locked in their employer housing and instructed to be cheerful by drones that fly around....

 

The problem I have seen with most remans is the clearances between the gears in the box. Those are generally NOT replaced. From the factory, they are a bit tighter over center, as the box wears, it isn't possible to get that tolerance any more, without having it too tight off center.... (and the vehicle tends to want to go any direction BUT straight down the road.) To me, that's why "New" has a pretty good appeal to it.

 

Interesting discussion- particularly that is seems the boxes were apparently problematic from the factory- but the "good ones" are like gold. Usually, poor design (like the entire front end suspension) is evident throughout.

If my truck were low mileage, I'd consider the rebuild more. But 307K and 25 years tells me there's GOTTA be some wear on the metal to metal surfaces, no matter how well adjusted and lubricated- and no way to know that until it's torn down. Even though I've had no issues to date, doesn't mean it's not a week away, right?

Honestly, I wish I weren't so dedicated to the old girl. But she's exactly what I wanted in a work truck back then, and to this day. Full 8' bed, rubber floor, back seat to throw **** and the occasional passenger. Besides, spending six figures on a truck- that used to buy you a house- just makes my head spin. So, as long as the 5.9 keeps chugging along (and who knows, maybe after) I'll keep her. Should have the time to replace the box over the holidays, I'll report back on the results.

Thanks to all for the input.