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Old 12-18-2017, 01:19 PM   #1
Mini-Skoolie
 
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Unhappy Cracked the steering Gearbox!

So, slightly annoying to say the least.

the bus has covered 80k miles and on the weekend, went to move it in the yard. Very slow full lock right, i could hear the power steering make a slight 'whine sound' of what i thought was normal for a hydraulic system? Of which it then made a relief sound.
Sure enough once parked, it was pouring out hydraulic fluid from the crack shown!



Emailed a few gearbox steering engineering places in the UK.

Some of the suggestions were welding the disk? whilst attached (But limited welding experience myself and its cast, which needs pre heating/ cooling?)

Other suggestion was Liquid E metal repair (but that is a bit of a bodge in my opinion, we need it reliable)

One company said they can remake a disk from the old one, to which i can myself as i have access to a engineering workshop with skilled machinists.
I think this may be a good idea to try?



I have found this from a seller in the States, but requires us to send our one and i image (not broken)

So with shipping included etc, that will be near $1000 knowing they wont want our cracked unit.



Does anyone know of replacements that would fit?

Lastly is this common, how would it even happen, one place suggested a loose ball bearing loaded between it and the end cap and cracked it on full lock, one place suggested cold weather? but it was about +5 degrees C not -20!

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Old 12-18-2017, 01:50 PM   #2
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Personally I'd go to a junkyard to look for a replacement, but pay attention to the mileage on the donor vehicle. Also, I think that's what people are talking about when they say don't turn the steering wheel so far that it makes that whining noise.

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Old 12-18-2017, 01:59 PM   #3
Mini-Skoolie
 
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Quote:
Originally Posted by Robin97396 View Post
Personally I'd go to a junkyard to look for a replacement, but pay attention to the mileage on the donor vehicle. Also, I think that's what people are talking about when they say don't turn the steering wheel so far that it makes that whining noise.

Your bus education begins.
I think so too! I didn't know turning the wheel so far could damage it! once fixed i will be seeing if theres a way i can weld a deadstop to the underside carriage to stop it happening again.

Sourcing a new one of these will be fun, more so that im a million miles away from the states!

All the best
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Old 12-18-2017, 02:04 PM   #4
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Quote:
Originally Posted by Robin97396 View Post
Personally I'd go to a junkyard to look for a replacement, but pay attention to the mileage on the donor vehicle. Also, I think that's what people are talking about when they say don't turn the steering wheel so far that it makes that whining noise.

Your bus education begins.
Not too many American school buses in England! That would be like trying to find parts for a Bristol RE or Mercedes O-603 in this country.

Isn't there a poppet valve (or several) to relieve over-pressure? Has it stuck? I would replace all of them if you repair the cover. Or find out what the maximum working pressure is for that box, and then use an external pressure relief valve to prevent over-pressure from even reaching the box at all. I did that for my hydraulic fan motor after a brand-new replacement motor burst after just 6 miles - the brand-newer motor now has a Prince RD-1875H relief valve to ensure no more problems.

Happy whatever from the colonies (I'm from Norfolk),
John
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Old 12-18-2017, 02:13 PM   #5
Mini-Skoolie
 
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Thanks John, I know! The struggle is real! i would of assumed it had pressure relief valves, as those mechanical pumps being extremely high pressure.
Im half tempted to see if there is a more modern design i could make work and retro fit to some sort of plate maybe?
But that may require changing the pump etc and would actually not be worth it.

It looks like i can buy an overhauled one from the states for nearly $1000 delivered which is mad!
However im waiting for some more companies to get back to me also.

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Old 12-18-2017, 03:18 PM   #6
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doesnt help a lot now.. but NEVER hold the steering wheel at the full lock position.. that whine you hear is the pressure going sky high as it tries to turn against the lock.. when you hit the end, back the wheel off by just an inch or so.. it will not affect your turning radius and your power steering system will be much happier..

I posted in your other thread... didnt realize you are in the UK.. these devices are often wanted back because peiple re-manufacture and re-sell them.. so they need the "core" its hard to find brand new older parts that wont cost twice or more as much as the new box and shipping your old one back.
-Christopher
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Old 12-18-2017, 03:44 PM   #7
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A core typically only needs to be "rebuildable". And yours certainly is.


And the hold short stops are a good idea. My little 4BT runs something like 1500 pounds of pressure as normal.
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Old 12-18-2017, 03:50 PM   #8
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Pry out the snap ring and look at the inside of the cracked cover. Check it carefully for signs of the shaft it covers having pressed or rubbed against it. If you find such damage it indicates that the bearings and or bushings in the gear are worn and the gear will need to be replaced. Also, while the cover is off, have someone turn the steering wheel back and forth (engine off) and watch for vertical movement in the shaft. That movement shouldn't exceed a couple of thousandth of an inch. Jack
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Old 12-18-2017, 03:52 PM   #9
Mini-Skoolie
 
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Thanks a lot for the replies guys. I’m already learning a lot haha!

I will see if I can get an end cap machined out of billet at work, then rebuild it (I build things like this as my day job so shouldn’t be too much sweat)

Has anyone got a good supplier I could use for a rebuild kit?

I have had a quick look myself, with not a great deal of luck for that box. Most of them were for Chevys and more car related.
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Old 12-18-2017, 03:54 PM   #10
Mini-Skoolie
 
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Thanks for this, this also sounds like a good idea, I’ll do this, I’m tempted to take the box off anyway and rebuild it with new bearings and seals. Can’t imagine the wear is too excessive as it’s a 80k mile bus not say 300k

But I may be completely wrong!

Again thanks for some good advice all the best
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