I'm hoping to preserve this somewhere because I won't remember. I had the opportunity to compare 3rd Gen and 2nd Gen steering boxes today.

Mounting holes: the bottom two line up fine. The top one is off maybe the diameter of the hole. This would be one of the bigger challenges but I think it could be made to work

Pitman arm: the splines appear different so you'd have to use the 3rd Gen arm. I don't know if drag link tapers are the same, but if so this is easy

Hydraulic lines: the pressure line is the same thread! The return line is larger but this 3rd Gen just had a short piece of hardline that then turned into hose and ran to a cooler. So, just use that factory fitting and hardline and then supply your own hose. Easy

Input shaft: definitely different splines, so you'd need the 3rd Gen pinch bolt female coupler. I doubt steering shafts are the same so you'd have to adapt this somehow. Either see if the baby u-joint is the same and install the 3rd Gen coupler or *I* would have no issue cutting and welding the shaft somewhere, provided it could still slide and collapse. I think this is the biggest obstacle to a potential swap.

I have no plans to undertake this anytime soon but the subject has always fascinated me. 2nd Gen boxes are terrible and becoming scarce

 

Are the 3rd gen boxes any better? Likely easier to find at this point, I'll give ya that.

I think cutting and welding would be a pretty simple fix for the connection at the steering box..... Or, even cutting the other end off the 2nd gen shaft, and grafting it onto the third gen shaft. And then we have the Borgeson shaft. Isn't it already correct on both ends???? Is it still available??

 

I don't know why exactly, but yeah the 3rd Gen boxes are better. They seem more durable and less subject to wander.

I replaced one today on an '07 at 231k. I used a reman MasterPro and it seemed fine. Little to no dead zone after installation. Maybe I just got lucky and received the one good reman, but I doubt it.

The '07 box was replaced because the shuttle valve failed and then you get normal assist right and no assist left.

 

There are 100% new boxes available so why bother?

 

In doing further research, guys claim to have lots of problems with 3rd Gen boxes, too. So maybe they're not that much better. I do still believe it's an upgrade, but perhaps less than I thought.

If I were retired and had endless time I'd love to try this, would be a fun project!

 

There are??? Where?

 

There was a thread about replacement steering boxes. There are 6 new ones on RA, Seems only two for my 8800 lb 2500. They say 100% new steering gears. https://www.rockauto.com/en/catalog/...ring+gear,7416

 

Thanks for the link. I note they also have shafts there.... though many folks don't care for the factory shaft....