I have a 1991 XJ. What is the best fix other than replacing the box all together. Is there a rebuild kit out there that you would recomend?

 

Welcome to CF.

Replacement boxes aren't cheap for sure. I've never had to rebuild one so don't know what's involved (YouTube!). The items with the hearts are the most popular:

https://www.rockauto.com/en/catalog/...build+kit,7397

 

I dont have a parts list, but here is a rebuild video.

 

Are you sure it's the box and not a line that's leaking?

If you don't rebuild the box correctly and make sure the tolerances are correct, it could be a wasted effort.
It might be better to grab a decent box from the junkyard. Also look into ZJ steering box upgrade - it's a popular upgrade.

 

If the leak is not too bad, you could try some stop leak liquid. AT205 Reseal
(sold at Advance Auto) has pretty much stopped my box's leak for over a
year now.

 

That's a nice upgrade!! Sportier steering.

 

Alot of that stuff works!!

I'm sure if the fluid is old and grungy it's not good either. Suck the fluid out of the reservoir and add fresh. Run it and see what happens.
Nobody ever changes their PS fluid it seems.

 

Funny you should mention that. I just started swapping out the power steering fluid in April every year a couple years ago.
Just what I could get out of the reservoir. With one of those cheap HF pumps.
Figure for the not even 12 ounces it takes why not.

 

I also do it with my master cylinder when the fluid gets too discolored.

 

Been wanting to do that too but not just the master cylinder.
A complete fluid swap out.
Been hoping to come across one of these for cheap used on Craigslist.


Not cause I need it.
I just want a new toy to play with. LOL.
But don't want to spend $150. MLOL.

 

I've rebuilt a couple steering boxes. It takes a lot of work. My take is it's not worth doing when there are inexpensive remanufacturered steering boxes available. the only exceptions are if it's something where originality counts (like certain classic cars) or you just want to know how they work inside.

Remember also, check the quality of your Jeep's intermediate shaft. Put a vice grip pliers tight at the bottom and strap it to the frame so it's doesn't move, then check the steering wheel. A little play in those intermidiate shaft U-joints or the slip-joint (or any rag joints) can easily translate into 1/2" or more of free-play at the steering wheel. Sometimes the steering box is fine but the shaft makes it seem sloppy. The last thing you want to do (if you can avoid it) is crank on the steering wheel when the engine is off. Tough on steering parts, especially for guys who run oversized tires.

Good luck!