[Healeys] Steering box rebuild

[Ray Juncal]

Over the years I accumulated enough stuff to rebuild three BN-1 / BN-2 steering boxes. This box has a 7/8" bronze bushing at the lower end of the steering shaft but the upper end of the shaft just rides in the aluminum of the case itself. In use both the bronze bush and the aluminum wear and cause play in the steering. You can replace the bushing but there will be no support for the top of the shaft that rides in the worn aluminum. The fix is to bore the case out to 1 1/8" and fit a 1 1/8"OD x 1"ID x 1" long bush at the top and a 1 1/8" OD x 7/8" ID x 1 1/4" long bush at the bottom. The bushings are standard size from Mc Master Carr catalog in the US.
 While you are at it cut the lip seal stop 1/8" deeper so the seal rides on a new place on the shaft. You can see the wear on the shaft ( red arrow in follow on post). If you have the skills and access to a basic machine shop this is not a difficult project. First the stripped and clean box is mounted on a milling machine table and the shaft center is located ( indicated ). Bore and ream to a snug fit. Cut lip seal 1/8" deeper before you take it off the mill to ream it. Press in the bushings and Bob's your uncle. You may have to take the shaft and case to a "honing shop" to have it honed to a precision fit if the bushings are too tight. See following post for more photos.


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