Hi guys: Anybody have any step-by-step instructions for re-building the PV544 steering box? I had about 1 - 1-1/4" play in the steering wheel, so I tightened the adjuster nut on top of the box & was surprised it turned about 1-1/2 turns! But that didn't take out the play, so I'm assuming the box needs TLC? Do you have to remove the box from the column & the idler arm etc etc?
Would appreciate somebody whose done this before, jumping in here. Thanks!

Thanks Eric for the ideas. I did check all the steering connector points with the front of the car off the ground, and didn't find any looseness in the joints. Went back to the steering box and basically tightened it almost all the way. That resulted in only about a 1/2" play in the steering wheel, so probably that's what I have to live with, unless I want to tear down the box?

With only 1/2" of play the box is likely adjusted too tightly. 1 1/2" can be considered normal. Get jack stands under the lower suspension arms and turn the steering wheel across the centre point. There should be no stiff spot at all. Adjust accordingly. There are no new worm and cog parts available so if worn you will have to do the best you can and live with the extra slop or search out a box with less wear. They are hard to find. Don't live with a leaking lower seal. If very minor leakage keep topped up. There may be bush kits for the PV box. They can be found for the Amazon box. Careful reaming required when fitting.

I’ve never delved deeper into a steering box other than making slight adjustments. But I’ve long wondered if it would be possible reclock the steering column and/or pitman arm attachments to the (splined) steering box shafts. This would bring less worn teeth together when the car is being driven straight ahead, often at highway speed where any play is quite obvious. The location of sloppiness would then be moved and felt when the car is turning left or right and traveling at at much lower speed and critical steering is less important. Is something like this possible?

No. It's critical that the pitman arm is fitted to the shaft in the correct position. There are witness marks on the arm and shaft to enable you to get the correct alignment. The arm should be pointed absolutely dead ahead when you adjust the toe in. After adjustment, if the steering wheel is off centre correct it then and only then. Don't centre it using the steering arms.

Thanks, Derek.

I have since taken a look at an exploded view in the Haynes manual (really nice old style pen and ink illustration I might add) and I see what you're saying. The steering column's worm gear looks as I expected but the driven gear on the pitman arm side looks different than I imagined. I thought that gear would be more of a complete, or nearly complete, circular gear that could be re-centered. But it looks like it's got just enough teeth to provide the necessary pitman arm travel and not much spare travel beyond that.

Have you checked all of the steering rod ends and center link ends for play?

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Eric
Hi Performance Automotive Service (formerly OVO or Old Volvos Only)
Torrance, CA 90502
hiperformanceautoservice.com or oldvolvosonly.com

No,but that's obviously good to do next. Will do & report back. Thanks.

I forgot to mention checking the idler arm for play as well.
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Eric
Hi Performance Automotive Service (formerly OVO or Old Volvos Only)
Torrance, CA 90502
hiperformanceautoservice.com or oldvolvosonly.com

Ok, will do.