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Old 02-06-2012, 11:43 PM   #8 (permalink)
IsaacCarlson
eco....something or other
 
Join Date: Jul 2009
Location: Colfax, WI
Posts: 724

wood hauler - '91 Ford F-250
Team Pontiac
90 day: 26.69 mpg (US)

Rav - '06 Toyota Rav4 Base
90 day: 26.52 mpg (US)
Thanks: 39
Thanked 67 Times in 50 Posts
Victory!!!!

I used the manual box for a 1990 f-250, but had to modify it some to get the pitman arm to fit.

There are two differences between the power and manual box.
The flat that is machined into the input shaft, is on the opposite side.
The indexing splines on the output are off by 1/8 of a turn.

I solved the first problem by pulling the end of the steering column out, turning it a 1/2 turn and sliding it back in....10 second fix.

The second problem took a dremel, cutoff wheel, and a steady hand. I had to grind out 4 splines to re-index the pitman arm. This worked great and the box is now in place.

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1991 F-250:
4.9L, Mazda 5 speed, 4.10 10.25" rear
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