My 1977 Ford F250 power steering box is a bit loose on the bottom sector shaft journal. This was a $350.00 "rebuilt box" but it looks like the only thing rebuilt about it was a resealing job. I opened it up and the main issue seems to be the lower end of the sector shaft, (nominal 1.375 dia), is worn about 0.003" and the housing bore is ovaled out about 0.015". The sector shaft on this box has no bottom bushing or needle bearing. I'm thinking about boring the housing for a Torrington needle bearing. The sector shafts are no longer available, so it will need to be repaired.
By strange coincidence I found a Eutectic Rototec spray welder kit new in the box on Craigs list today. It came with with a supply of unopened spray powders. It's more or less a oxygen/acetylene torch with a feed hopper and a tool post mount setup for for spray welding. According to the manual, the Rototec process is a "cold" process that does not heat the shaft over 500 F, I'm thinking about using it to build up the worn journal area on the shaft. One of the powder formulations is recommended for build up of bearing races, so it sounds possible. The other alternative is bushing the housing with a bronze bushing. This would have lower unit loading than a needle bearing on the shaft overlay. Comments?