'97 Steering Gearbox Replacement Guidance

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crowfather

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So i took the gearbox apart today, cleaning as I went. I was following this video:
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It is very thorough.
Everything looks mostly in good order so I am just going to replace the seals and o-rings that came with the rebuild kit. However, I do have a few questions that may or may not matter.
1. The pitman shaft splines have a cut through them from looks like a grinder wheel. Would this cause any slop? The rest of the shaft looks good. See attached photos.
2. There looks to be some retaining ring/clip in the bottom of the box casing, between the piston side and the stub shaft side. That wasn't mentioned in the video or elsewhere online. Should it be in there? Also shown in photos.
3. The worm gear looks to have some markings on it. I don't know if this came from the factory that way or not. Look at the photos and tell me if it looks strange please.
4. It looks like somebody tried to install a universal joint before, because the tip of the stub shaft is cut off. I don't think this matters but I wanted to point it out.
5. All my ball bearings are the same. The video suggests that half are black and half are metal. Is this evidence that somebody used the wrong ball bearings on a previous rebuild?
6. The casing had a bunch of sludge in it. It smells a bit like burnt gear oil, not quite that bad but the same flavor. I wonder if the orange color is a mix of different fluids over the years cooking together. Makes me think it was never rebuilt, contray to the last comment. I used a whole can of brake parts cleaner getting everything clear of fluid and gunk.

The rest of the components look good. No marring on the teeth of the pitman shaft or the teeth in the piston. No play in the bearing of the pitman shaft. Everything came apart rather easily, the lack of rust probably helps.

Has anybody painted one of these after a rebuild? I want to avoid rust in the future and maybe paint will help.

Thanks
 

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crowfather

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Here are the rest of the photos.
 

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crowfather

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#5 above has me kinda worried. I can somewhat see a coloration difference on some of the bearings, but not 12 of them. I read that one size is smaller than the other but I cannot break that out with my calipers. The sizes are so close. Any idea on how I can proceed?
 

east302

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Sorry, I’ve never torn one down but if in doubt I’d buy new ones from GM if they’re available. Do you have the factory manual? It should have the rebuild procedure in it and may cover the bearings. 1997 is in post #92:

 

east302

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For 1998, the steering gear is in volume 2 and says that the black balls are smaller than the silver ones. It says they are to be installed alternately but doesn’t really say which one goes in first in the sequence.

You must be registered for see images attach
 

Caman96

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This picture from ebay seems to show the dark are smaller.
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crowfather

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I’d be replacing every wear part available.
Thanks so much! I found that part number just before your reply. However, I only saw it elsewhere for $60. I'll have to bookmark this one, in case I need other parts.

Visually, most of the parts look in good order. I could replace the bearings($100), but they don't show much wear and the steering was quite good other than the play on center. I suspect a proper adjustment would've fixed that. I only went down this road because of the inspection results requiring a seal replacement. The steering was rather good otherwise.
 

crowfather

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For 1998, the steering gear is in volume 2 and says that the black balls are smaller than the silver ones. It says they are to be installed alternately but doesn’t really say which one goes in first in the sequence.

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Yeah I read this part. I cant reliably figure out which are smaller with my calipers. Might need a micrometer.
 
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