JOB IS DONE
Ok. Here is the 411 for removing the steering box on a 93 K1500 Suburban 4wd. (It was great to have a compressor and air tools, but they are not required.)
1. I pointed the wheels straight.
2. Then I put the left side up on a jack stand, and removed the drivers side wheel for better access.
3. Removed the power steering lines.
4. Disconected the steering shaft.
5. Disconnected the pitman arm from the link, using a pickle fork.
6. Unbolted the 3 bolts holding the steering box to the frame and lowered the steering box out and away.
7. Took the steering box with pitman arm still attached and had the machine shop at NAPA remove the pitman arm for transfer to the rebuilt box. (You can remove the pitman arm yourself using a puller that can be purchased or rented.) I had the machine shop at the NAPA store remove it because they have a hydraulic press and can remove it with ease. They elected not to charge me for the service since I bought the rebuilt steering box from them.
8. Using an 1 5/16" socket I tightened the nut holding the pitman arm to the steering shaft.
I reversed the other procedures reattaching the pitman arm to the steering link, etc.
Other notes: You will have to do your best to align/center the steering wheel when attaching the pitman arm. I did an eye-ball wheel alignment since I positioned the wheels before starting. I expect to have the alignment checked if it pulls left or right, but so far so good. Top off the power steering fluid and cycle the steering lock to lock to get air out of the lines. I had a lot of foaming fluid in the power steering pump, but it settled after I let it run awhile.
The nut that holds the pitman arm to the steering shaft is 1 5/16. I bought the socket from NAPA and the 1" to 1/2" drive adapter. You will need to rent or buy a pickle fork and a pitman arm puller if you don't already have one. Otherwise basic hand tools are all that are needed.
Cost: Rebuilt steering gear: $180.00
Couple of pints of steering fluid: $ 9.00
1 5/16 socket and adapter: $41.00
It was a five hour project including lunch. It was a lot cheaper than the $750 that the shop quoted me. A good way to spend an afternoon getting to know my burb a little better. Besides with the money I saved, I'll be able to spend a little extra on tires when I'm ready for those.