So that catches us up to my last days off 5/04. I had been fighting the power steering getting worse and worse over the last few months. I finally broke down and bought the parts. I first thought I would just replace the pump, but my PS box has been loose since I bought the truck so a week later I started looking into steering boxes.
I got the upgraded power steering pump kit 68102457AA which is actually separated into three separate parts. I was able to get a good deal on the parts at one of the local dealerships.
The pump and pulley - $488.40 w/ $50.0 core
The reservoir - $80.03 w/ $10.00 core
A bracket - $39.00 w/ $5.00 core
New Pump (picture from the net)
This would be the stock pump for my generation.
After much research I went with the upgrade "big" box from Dodge rather than the Red Head or the other popular swap. I liked the larger sector shaft and internals over the others. I couldn't get it from the same guy at the first dealership so I called around and Crown Dodge in Oxnard got real close to the best price I could find online. No one else budged on the retail price. Not having to ship any cores made the little bit extra worth it. The PN for the upgrade box is 68170214AA. This is the box, pitman arm, and inner drag link. I paid around $710 for the kit including the $75 core and two quarts of Mopar ATF.
Removal is fairly straight forward support the frame, remove both tires, remove drivers inner fender, remove fan shroud, remove serpentine belt, remove inner drag link from pitman. Pull lines from PS cooler and drain, Remove lines from brake booster, remove lines from PS box, Remove 2 of the three bolts holding the box to the frame, Remove the last bolt while getting ready to catch the box, lower the box, remove the lines from the PS pump, remove the pump.
Install everything in reverse. Issues I had were: The new box is a lot bigger and heavier, as such the PS lines off the pump and box need a little help finding fitment, and it took a little more struggle holding it there while I got the first bolt started. I installed the new inner drag link that comes in the kit loosely into the pitman arm while cycling the steering to remove air. This broke the threads off the tie rod the second time it wet to lock. That was a $100 ($160 retail) oops. The nut to attach the pitman arm is a 1 15/16" socket. No one had it for sale and most shops didn't even have one to use. Ultimate Truck Performance sent me to Big Brand Tire as that is were they go to borrow it.
The truck steering is fantastic now. I no longer fear pulling into parking lots. It is also real tight and I no longer get feed back crossing sharp bumps through corners.