Catastrophic power steering box/sector shaft failure in the County

[GRUG]

So I had just pulled over in my 1985 4BD1 County a couple of days ago, was reversing to straighten up my park, and CLUNK! Sudden loss of steering - the steering wheel was just spinning loose.

After feeling very lucky that I hadn't been doing 110 km/hr with the family in the car, I also felt lucky I took out roadside assist when I purchased the blue beast.

After a tow to safety, it appears the sector shaft in my steering box has failed, as the shaft had dropped down out of the box.
I'll post photos of the sheared shaft when I get a chance.

So it appears there aren't too many 3 bolt boxes around, but the 4 bolt is a fairly easy retrofit with a few hose adaptors.

A reco 4 bolt box is around the $900-1000 mark, plus $40 for the adaptor kit.
A brand new 4 bolt box is $1500-2000, plus $40 for the adaptor kit.

I was angling towards a reco box due to funds being tight, but I'm having second thoughts, as I really don't want to experience steering failure ever again.

So my question is - fit a reco box, or a brand new one?
Any reason to suspect this might happen again anytime soon?

150153150154

[manic]

Never heard of that happening before. I have replaced a worn out 25+ year old 4 bolt, but it showed no signs of letting go. They are tough units.

Your drop arm looks to be an aftermarket replacement judging by the red boot clamps. Aged arms are notoriously hard to separate from the shaft. My guess is that the old one was flogged with a BF hammer during attempts to remove it, damaging the shaft in the process.

[justinc]

Have had one do this, a 4 bolt in a defender that "kissed" an embankment while the driver was holding onto the steering wheel for dear life... the twist and subsequent shear was spectacular. The main reason why I don't fit anything but new, or used boxes only from a known driveable not crashed vehicle that we have disassembled ourselves. Any insurance quotes that I do automatically include a steering box if the vehicles have significant rim, tyre, or steering arm damage too.

[JDNSW]

This is the first one I have heard of, so it certainly is not common.

[rick130]

One was reported on here a few years ago in a 120.

Put him through a fence on the farm, it was a fatigue failure.

[JDNSW]

A few years ago a relative of mine had a tooth come off the rack (and jam steering) on her Corolla (around 300,000km), fortunately at low speed. Only one of that I have heard of.

This sort of thing may be becoming an issue as more vehicles do a lot more kilometres than has been usual in the past. Thankfully, I replaced the steering box on my County about fifteen years ago (it has now done over 640k km.).

[GRUG]

I've decided to go new for peace of mind.

It's worth noting the County only had 160k on the odo, but who knows how it has been treated in that time.
It has standard wheels/tyres/offset. As shown in the photos, it has had the suspension changed out, but it's not a lift as far as I know.

I found a few links discussing similar failures:
Catastrophic Steering box failure! (https://www.aulro.com/afvb/technical-chatter/137207-catastrophic-steering-box-failure.html)

Serious failure of steering box - Defender Forum - LR4x4 - The Land Rover Forum (https://forums.lr4x4.com/topic/67533-serious-failure-of-steering-box/)

Problems with defenders steering sector shaft (https://www.aulro.com/afvb/90-110-130-defender-county/125447-problems-defenders-steering-sector-shaft.html)

I'll post pics when the shaft is removed.

[manic]

Well then, I'm glad my replacement was new 4 bolt adwest.

These boxes can be abused offroad for decades without ever experiencing this failure.

In the case of OP with what looks to be a relatively low km straight and well looked after county, one would think there was either a manufacturing anomily or the arm/shaft at some point in its life has been struck hard, resulting in stress fractures and eventual failure.

I am sure I have read a few drop arm removal posts where people have attempted to whack the **** out of it! Perhaps there is a link here.

[GRUG]

Just bad luck I guess... Could have been much worse though!

Assuming the drop/pitman arm has been replaced, can anyone tell if it's standard duty? If it's HD, I'd rather refit a standard duty arm and possibly have it bend next time instead of transferring force through to the shaft (?)

The existing arm will be getting pressed off, so no hammer treatment this time around

Going with a genuine, new 4 bolt box for ~$1400 + hose conversion kit

[manic]

New boxes usually come with a new arm. If not, dont carry across the old one, put a new one on. The boot on your balljoint there looks like it is beat, I wouldn't carry that across.

[GRUG]

Of course these ones don't haha

I have ordered a new arm for an additional $130

[Plutei]

Nothing to do with steering but congratulations on buying that County Grug! I was absolutely salivating over it while it was on carsales and I hope it will be a great purchase; certainly looked in good nick, steering box aside...

[GRUG]

Nothing to do with steering but congratulations on buying that County Grug! I was absolutely salivating over it while it was on carsales and I hope it will be a great purchase; certainly looked in good nick, steering box aside...

Thanks Plutei

After spending what I did on the County, spending another $2k on repairs only 3 weeks in is a bit of a sore point at home 😬

I love it though. Most enjoyable drive I’ve ever owned. Interesting considering it’s slow, noisy, doesn’t corner well, or meet any of the typical measures of an enjoyable drive. Sure gets plenty of attention, passing comments and waves, and already a couple of offers to buy. One bloke stopped me for a solid 30 minutes to chat about it.

Here’s hoping it’s back on the road next week.

[Bearman]

I have heard of sector shaft failures on 3 bolt boxes years ago when they were plentiful. I have one and possibly 2 of them here if anyone wants them.

[justinc]

I have heard of sector shaft failures on 3 bolt boxes years ago when they were plentiful. I have one and possibly 2 of them here if anyone wants them.

Definitely need one down here Brian, to go into a 76 RRC that is being restored. Can you PM me a price? Customer only asked about one on Monday so good timing!

[rijidij]

I know of two similar failures, both 3 bolt and both broke while turning at low speed.