Recon steering box issues

Hi all, not posted in yonks but could do with some advice if possible please. 2001 disco 2, fitted recon steering box to cure usual leak, first box supplied leaking from the top seal, contacted supplier, they apologised and sent a replacement. Replacement fitted, now there is a loud clunk when turning the wheel just before it reaches the stops in both directions, tried to upload a video of this but it won’t for some reason, if I hold the drop arm while someone turns the wheel, I can feel the clunk through the drop arm, it also clunks while driving, intermittently when cornering or hitting a pot hole etc. It was fine on original box. Contacted supplier as now lost faith! They said they would refund me if I return the faulty box as the symptoms baffle them and they can’t understand why it would clunk in this way. My question is could I be missing something? Ive checked Panhard rod bushes, all ball joints, radius arm bushes and steering column joints and anything else I can lever! I’m just loathed to take it out and return it to find the problem is still there when the next one goes in. Has anyone else known a steering box fault of this nature before?

Cheers

Who did you get the steering box off, are they reconditioned units or just second hand?

They are recon, from a company trading on eBay called Autosteer direct.

I'd try twiddling it with the column disconnected then the drop arm to pin point the issue.
The adjuster screw isn't miles out is it?

I removed the drag link yesterday again and cycled the steering wheel, there’s no clunk then. Only seems to happen when everything is under load. Shame I can’t get the video clip to upload here from my iPhone. I think the adjuster feels spot on, returns to centre fine, and just a tad tighter than the original.

Prob also worth mentioning, if I cycle to the right, it will knock just before the steering stop, then I have to go all the way left and it will knock just before the stop. Rocking the steering where it just knocked won’t make it knock again. Thanks for the replies so far.

Spray the steering uj’s with grease, if the noise goes away you need new steering uj’s

Get someone to do the wheel whilst you listen/feel for the knock.
Feel the pan hard rod, swivel housings, column whilst testing.

I’ll go out and lube them up now... stuck the clip on YouTube in link above. Thanks for the reply again

Flossie said:

Get someone to do the wheel whilst you listen/feel for the knock.
Feel the pan hard rod, swivel housings, column whilst testing.

Click to expand...

This really does sound like the best and simplest way forward to me for detecting the actual cause of the issue.

Hi all, I really do appreciate everyone’s comments, as in the first post, I can feel the knock through the drop arm more than anywhere else, but it is such a clunk it also vibrates pan hard rod etc. We greased steering column uj’s on reassembly. I’ve spent the morning on it again going over it all but I’m convinced now it is the box. Jacked the front up and turned wheels with engine off, no clunk, engine on and it does. I was looking maybe for reassurance that swapping it out again was the way to go, it’s not an easy job but I’m getting good at it now

Is the box centralised properly ? I.E. are you going too far in one direction and reaching the end of the travel in the box itself - causing the clunk ?

If you included your location ( nearest large town ) perhaps someone local could come and drink your biscuits and eat your tea

Found it... it’s the pan hard rod. Just went out and disconnected it, noise gone, refitted and it’s back. It’s the drivers side I think, not sure if it’s the bolt itself that might be slightly worn, it’s been off and on a few times lately doing various jobs. Thank you again everyone for your help, it all prompted me to check more thoroughly for a simpler cause. Thank god I don’t have to take the bloody steering box out again! Hats of to the recon company though, they were very professional suggesting I could return the box for a refund whether they found a fault or not.
Cheers again all

Flossie said:

Get someone to do the wheel whilst you listen/feel for the knock.
Feel the pan hard rod, swivel housings, column whilst testing.

Click to expand...

That Flossie bloke was near then.
Check the mount holes haven't gone oval, usually a shoulder worn in the bolt as well.

Cheers Flossie, I think it is the bolt, it wasn’t looking great, hard to believe such a small amount of ware can make such a Big Bang. I’m a lot happier now I know what the problem is.
Thank you again for all your help.

You'll find the handling improved once you've sorted that phr too.