Thread: 3 bolt vs 4 bolt steering box questions

Thanks for the headsup mate, that sort of advice is what a novice like me hopes to receive!

Originally Posted by isuzutoo-eh

Thanks for the headsup mate, that sort of advice is what a novice like me hopes to receive!

LOL this Novice took 2 hours to think of it, thats after removing, twice as much as i needed to etc

Alright, mine is now done. Only took 7 hours mainly due to inexperience, seized bolts, call aways and waiting for the hydraulic hose to be made.

My experience:
I used the cross arm that came off the 3-bolt/came on the vehicle.
The only hose that needed an adapter was the input hose from pump to box. I had a new hose made up to suit. Return line was fine, I was surprised to find.
D1 steering boxes require the steel bypass pipe to be bent to clear the steering pump output.
You have to lift the bloody engine a good 5 inches and raise the steering box to get it out, not drop it below.
To lift the engine a bottle jack on the diff and against part of the cast iron engine block works well. There is nothing useful to lever off!
D1 4 bolt steering boxes use the same spline count as the '85 110 3 bolt box i.e. the pitman arm goes straight on. You can't use the Disco pitman arm unless you change the rod it attaches to.
Have a spare dust seal handy even if you don't plan changing all the seals as it will likely get quite damaged.
The chassis needed the holes openend up for the 4 mounting bolts, they are slightly larger dia than the 3 bolt box. Drill three from between the chassis rails, the fourth from under the wheel arch.

You will use 4,565,151 common expletives, and invent 8 new expletives.
Hope that helps the next person-your experience will vary

Does anyone know the actual sizes of the fittings? i need to get some lines made up for a 3 bolt but i cant actally take my truck into for them to look at it.

We tried to put a 3 bolt from our 1985 RRC rollover into our late 1994 300 TDI disco, but motor hit top of the steering box when we started it. Had a Hydrolics place change the ends on our hose to make it fit. Then we put in the 4 bolt from the 1990 we want to sell, and got hose from wrecker to suit, but had to change an end yet again. That 4 bolt leaks bad. Thinking of trying heavy gear oil instead of power steering fluid.

Now 3 bolt which we think was rebuilt before we purchased the 1985 RR that my son rolled, is to go into our 1990 RR, but we will not have the hoses for it--it is to be sold soon, sent first photos to an AULRO member, and another member has also inquired--We think this 3 bolt was our only good box, not counting the steering box on our new raised 1995 disco--a different one to the one mentioned above.

Fun changing boxes--we also put into the 1994 disco a box from the wreckers, but got our money back on that as it also leaked bad. In all weput 4 boxes into the disco laying under it in our muddy drive, and all exept the three bolt leaked, and the three bolt hit the motor-

Next time do recond we should just fork out for an exchange box, but did not have the money at that time, so had fun learning instead.