"7/16-14UNC x 3.75

bolts available at 4" or 4.5" $3.80 each

https://www.hi-tensilebolt.com.au/

I am thinking to simply place some 1/8" sheet alongside the frame rail, and use the slightly longer bolt

my presumption being this will reduce the concentration of stress upon the frame rail around the bolt head, and distribute it more evenly

reduce risk of frame rail cracking is my goal here

anyone disagree?

It looks like a great product Rustynuts, so who would install this if I had no mechanical experience? Is it a steering and suspension specialist? A mechanic? I might suspect some will not want to install non OEM or equivalent aftermarket products for liability reasons....

Also, how long is the stock steering box good for? Mine is 23 yo, and is coated in rust, but the steering is fine. Has anyone installed an aftermarket steering box? If so, what brand is it, and are you happy with its performance?

I'll get under and check, may replace the bolts with grade 8 or 10 for safety..... my XJ has 150k on it now so it hasnt been used much, I'll keep an eye out though.

Can anyone elaborate on steering box bolt specifics for XJ TD please?

I bought replacement bolts from C-ROK - http://www.c-rok4x4.com but they're too short to make it through my frame & reinforcement plates (C-ROK's own). I realise TD wasn't a US spec vehicle, but you wouldn't expect bolt length to change.

Don't have mine to hand to measure unfortunately - but seem to need to be longer than 3.5" / 4"..... ?

I doubt they would be different to the petrol XJ, which are 3.75" long + 0.25" tip

therefore, if any plates are fitted that add additional width, a longer bolt would be needed.

I would measure & compare everything

You could email C-Rok and ask what is the go...they may have just sent you the wrong bolts

or order the 4.5" bolts from the source above I quoted (or obtain locally)

My 95XJ Sport has been owned since new....

Although the recall was completed along time ago, I still have reservations about my steering box due to its age, the age of the bolts, the rusted over nature of the box, not to mention the fatigue on the body. Basic wear and tear over 23 years of ownership.

Lets say I replace the steering box (due to age if nothing else), and the box is bolted to whatever reinforcement Chrysler Jeep Australia performed in 1997, I could add the Ironman steering brace as an extra measure right?

Would a regular mechanic do this, or would they shy away from installing any non OEM piece on the car due to legal liability reasons in the event of failure0?

My other alternative is to take it 200km into Sydney to a trusted Steering and Suspension specialist that I have used before...

I highly recommend the "IronmanFab4x4" RHD steering box brace. Ordered it with the spacer that goes between the box and rail and the sway bar relocation brackets. Was simple to fit myself. Fitted perfectly and has really made the box not flex the rail. Steering is more direct too. Well worth it IMHO.

Has anyone changed their original power steering box? If so, what did you replace it with? At 345K and 24 Yo, I am looking at the state of the hydraulic hoses, metal fittings on the hoses, the rust or oxidised metal coated steering box, the steering arm, and think that it is next on my to do list. At this stage I have the OEM tyre size but one day could fit something larger, but not overly large.

Can the original steering box be reconditioned? What OEM replacements are available? I only know of PSC, as an alternative to Crown, and Omix/Ada.