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I recently removed my Steering Gear box for a rebuild, and upon taking it apart, found that the gears were toast. I ordered a rebuilt box and Installed it, but I am having trouble with the pitman arm. It doesn't seem to be going all the way up on the pitman arm shaft of the steering box. With the nut and washer on, I only have 1 thread showing. From the looks of the Asm. Manual a 1/4 inch should be showing. The teeth are lined up and I have removed the arm and tried again with no luck. Is this normal?
If Gary (GTR1999) doesn't reply to this thread look up posts by him. He had detailed pics of a steering box rebuild that will probably show the correct position of the Pittman arm.
The pitman arm doesn't go all the way up. I believe it its designed that way so you can get a pitman arm puller on it if you need to remove it. Just make sure you torque it to the proper setting.
My Chevrolet Chassis Service Manuals say torque the Corvette pitman arm nut to 140 ft-lbs. The pitman shaft is tapered and that torque will draw the pitman arm onto the taper. I would imagine that manufacturing tolerances would allow for variation in the amount (or number of threads) sticking out from the nut and lock washer after applying the correct amount of torque.
Once you torque things to 140 ft-lbs that arm isn't going anywhere.