I bored my fitting out to 7/32" and I enjoy the lighter steering. It's not too light got highway driving IMO either
I did 7/32' to start as well. It was perfect on the highway/street, but not enough assist off road running 35's and front/rear lockers.
That's the thing here. I did the swap for three reasons.
1. My stock XJ box was questionable. It's old, and I've beat the hell out of it. I suspected it may have been on it's way out, and I wanted to eliminate it as a possible source of some popping I've been getting on articulation (wasn't the box, but oh well).
2. My stock pump was whining due to aeration and I couldn't find any leaks. I suspect it was the seal at the pulley.
3. I'm running 35" tires and front/rear auto lockers, and I do a lot of bush runs, and I guess I'm a wimp. I just don't like having to two hand my wheel to get around a tight corner, in off camber situations. Plus I like to keep my coffee hand free.
The difference off road is night and day with this swap. The throw of the durango box is definitely less than stock, but it worked out perfect for me because my 35's were rubbing at full lock on my sway bar mounts and the tie rod was running into the diff cover and coil buckets (buckets trimmed as far as they can be, and still hitting with that 1.5" tie rod).
The throw of the Durango box maxes out with about 1.5mm from my diff cover and buckets and leaves me with 4-5mm of clearance at the sway bar mounts.
Even with the decreased throw, the extra assist means I'm getting to lock faster and I found last night that where I was doing 1 point turns stock, which turned into 2-3 point turns with just the Durango box, I'm not back down to 1 point with the extra assist. It's definitely a worthy upgrade, but I just don't see how MOST people would drive this on the highway.
I'm keeping an eye out for a 1/2" hydraulic valve and variable actuator (no idea where I'm going to find this). I figure I can either tie the actuator/valve to my speedo and automatically decrease pressure to the box when I get above 50km/h, or I'll just throw a switch for street/trail.
Once I get this all figured out, I'll do a proper write up. I can't believe the misinformation on the subject of the Durango box and the WJ pump.