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While on the fifth Annual Jeeps Unlimited Moab Run in May, 2005, my energy steering pump that serviced the Hydroboost and my steering field was fading quick (and I do imply quick). Vanco helped me out and we acquired a pump from PSC despatched over-night to my motel. It was a short lived repair as I used to be ready to put in a brand new pump with a distant reservoir as soon as it turned accessible. Enter Performance Off-Road Systems from Wetumpka, AL. I spoke at size with the proprietor, Sean, about pumps and different hydraulics. His firm does a good quantity of steering setups, rams, and ram assists. Sean despatched out a pump and reservoir and I picked up the hoses and hose fittings domestically and ordered a mounting bracket from PSC.
This wasn’t a “equipment” so it was as much as me to acquire the required hose and connectors to get it into the TJ. The pump is rated at 4 GPM (Sean says it can movement a bit greater than at) at 1450 PSI. The distant reservoir holds extra fluid than the smaller reservoir that’s hooked up to the manufacturing unit pump. The reservoir has a return becoming on the underside whereas the suction connector sits low on the facet of the can.
The reservoir incorporates a filter which additionally serves as a baffle. This is the highest of the reservoir. Power steering fluid will increase a bit when it will get sizzling so don’t fill it to the highest. The bigger reservoir additionally serves to behave as a cooler (of kinds). It doesn’t exchange an everyday PS cooler, for my part, however having this distant mounted from the pump offers you extra fluid capability and a cooler operating system.
A fast look into the suction port reveals a little bit of the filter that’s mounted within the reservoir. The outlet is a -10 AN becoming and the return line is a -6 AN line.
My unique PS pump configuration (from Vanco) had the return strains from the steering gear field and the Hydroboost coming collectively at a T becoming after which going into the pump reservoir. While this works, I’m fairly positive that the movement is being restricted previous to reaching the reservoir (when the movement is at most).
Having two return strains going into the reservoir can be the best setup. Unfortunately, that may not be simply achieved with the inventory pump reservoir. I picked up a weld in male -6 becoming so as to add to the brand new reservoir. This explicit one is made by Earl. I consider the half quantity within the above image is the Earl # and never the stock quantity from the shop I acquired it at, which was a efficiency velocity store. A very good good friend of mine was type sufficient to weld it to the reservoir as soon as I had made the outlet within the reservoir. The becoming runs about $4.
Power Steering Pump & Remote Reservoir
Next comes the fittings for the suction line that connects the reservoir to the pump. I picked up a pair of Russell -10 Twist-Lok fittings, half # 624030. This particular connector is NOT designed for prime stress purposes (similar to energy steering). Basically, they’re an AN-10 feminine becoming with a hose barb on the opposite finish. Using a Twist-Lok connector in a excessive stress utility can be a mistake. But for the suction line, these are simply what the physician ordered. They value about $9 every.
The Twist-Lok becoming is a slip match. The purple ring has a slit down it that may be expanded with the blade of a screw driver. This is unfold and slipped down over the hose. The hose is then pushed onto the becoming till it’s cosy up in opposition to the shoulder of the becoming. The purple ring is then expanded once more and slid up over the hose till it butts up in opposition to the becoming physique.
A pic of the hose I used for the suction line. Made by Aeroquip, this hose is -10 (5/8″) diameter and rated at 250 PSI. This hose is pretty inflexible, which is required, so the road doesn’t collapse flat from the suction of the pump. (the identical manner you may collapse a ingesting straw by sucking too onerous on it) The value is about $5 per foot. I requested for two toes and the counter man had an finish of the roll piece that was 31″ lengthy so I acquired the additional half foot without cost.
I additionally purchased a pair of Russell -6 Twist-Lok fittings for the low stress return strains. These will join the return strains to the reservoir, these from the hydroboost and the steering gear field. The fittings have been about $5 every on the native Checker Auto retailer.
The hose clamp within the above pic was not included with the becoming. I’m opting (until I modify my thoughts), to make use of the hose clamps on these low stress return strains. These barb fittings are rated for 250 PSI with out utilizing any clamp, per Russell’s specs. However, I’m pondering that I’d simply as quickly be on the protected facet right here. Having a hose come free out on the path can be the pits and it could make a multitude that requires a great clear up…..avoiding all the scenario can be simply high quality by me.
I acquired the mounting bracket from PSC earlier within the week. Prior to ordering it, I verified that the reservoir they promote with the pump kits was the identical diameter as mine. Once the scale was confirmed, I had the bracket at my home in a couple of days. It is an aluminum bracket that has 4 mounting holes and clamps across the reservoir.
Power Steering Pump & Remote Reservoir
Install day arrived (which means I had a day without work from work) and I headed as much as Troy’s store to do the work. We had beforehand mentioned his welding the additional connector to the reservoir. If I discovered the suitable becoming and made the brand new gap, he would hearth up the brand new Lincoln and make it occur.
I wanted to mock up the reservoir mounting location so I might decide the suitable spot for the reservoir’s new becoming. It didn’t take lengthy to disconnect the PS strains from the present pump and take away it from the inventory mounting bracket. (For extra step-by-step particulars on doing the pump removing, take a look at this PS pump replacement write-up.)
I had requested Sean about operating a inventory or undersized pulley on his pump. He instructed me that I might use both one. I’ve a PSC undersized pulley however you cannot mount the pulley onto the pump after which bolt the pump in place. The smaller diameter pulley doesn’t enable the holes within the pulley to line up correctly with the pump’s three mounting bolts. I took the better route and opted for utilizing my inventory pulley.
Before I might mount the pump to the bracket, I made a decision to take away the threads from a pair of the mounting tabs. The middle part was tapped and the bolt dimension/pitch matched the inventory mounting bolts….however I might see no motive for them so out they got here. A 5/16″ drill bit made brief work of them. With the threads out of the best way, I slipped the pump into the mounting bracket and used a single bolt to briefly maintain it in place whereas I acquired the reservoir able to mount.
As I write this, I understand I missed taking a close-up image of the mounting bracket whereas I used to be making it. This bracket was produced from some 1.5″ huge metal flat inventory, about 1/8″ thick. I lower a bit that was the identical size because the aluminum reservoir bracket. The reservoir bracket has 4 5/16″ holes in it. I transferred the outlet sample to the flat inventory and punched out the holes. The metal bracket was then bolted to the aluminum reservoir.
With a flapper disc hooked up to a 4″ angle grinder, I eliminated the paint from the motive force’s facet grill assist rod, close to the neighborhood of the ability steering pump. I briefly eliminated the radiator overflow bottle and the TJ’s windshield washer reservoir. I wanted some house and these have been in the best way as I attempted to place issues, measure for hose size, and so forth. As I discovered what I believed was an appropriate route for the hose connections, I’d slip the washer reservoir into place to make sure I had correct clearance. Satisfied that I discovered an appropriate location for the reservoir, I marked the spot on the reservoir the place the outlet can be drilled for the AN becoming.
Before I might drill the outlet within the reservoir, I wanted to open it up and briefly take away the filter. I didn’t need the filings from the drill entering into it. I eliminated the nut on the prime of the baffle plate, which additionally serves as the highest of the reservoir. With a little bit of effort, the highest was pulled out of the reservoir. The rubber o-ring, as seen within the above pic, retains it snuggly in place.
You can see the filter on this pic. It is held in place with an aluminum filter retainer and one other nut on the threaded rod. I eliminated the nut, the retainer, and at last the filter.
With the filter out of the best way, it could be simple sufficient to scrub the filings out of the reservoir after I completed drilling the outlet. After making a small pilot gap within the reservoir, I completed the job with a step drill bit. They work nice for this sort of activity whenever you want a gap about 3/4″ in diameter.
I handed the gutted reservoir, with a recent gap in it, over to Troy. A few minutes later, I had one extremely popular reservoir with a model new -6 male AN becoming welding into place. Thanks Troy!
When the reservoir had cooled, I put in the filter, put the highest again on the unit, and slipped it again into the aluminum mounting bracket. I bolted the aluminum bracket to the metal bracket with 4 mounting bolts. I then clamped the metal bracket onto the grill assist rod with a Vise Grips. After rechecking the placement yet another time (I wished to ensure it could clear every little thing), I tacked it in place with the welder. After one other examine to ensure I might route the hoses within the method I wished, I welded the bracket to the assist rod. (Did I point out that is a kind of measure 3 occasions, weld as soon as type of steps?)
Here is a pic I snapped after the set up was completed. You can see the mounting bolts on the aluminum reservoir bracket. As I mentioned beforehand, it’s bolted to the metal bracket that I welded to the assist rod.
Power Steering Pump & Remote Reservoir
With the pump reservoir tacked into place, I turned my consideration to creating up the suction line from the cool blue hose I had purchased.
The Twist-Lok fittings are simple to assemble. First, guarantee the top of the hose is lower squarely. If it’s not, use a pointy knife to make it so.
Slide the purple cowl over the hose, pushing it onto the hose about 4″. Push the Twist-Lok becoming into the hose. You are completed when the shoulder of the becoming is flush in opposition to the top of the hose. Using a screwdriver (or one thing comparable), pry open the duvet a bit, sliding it in direction of the top of the hose till it too is flush to the sting of the connector.
Here is the -10 becoming after it was hooked up to the Aeroquip hose after which related to the reservoir outlet port. Remember that the Russell fittings proven listed here are produced from aluminum. You ought to NOT be leaning on the wrench too onerous. Just a great cosy match is all that’s required for a leak free connection.
Remember to observe your bend radius on the Aeroquip hose. If you attempt to change instructions with it too rapidly, it can begin to collapse. The bigger the hose, the larger the bend radius. In the above pict, you may see the opposite -10 becoming within the background, which connects to the pump’s inlet port. I routed the hose in 270 diploma bend between the reservoir and the pump and used about 20″ of hose. I might have used much less hose by using a few 90 diploma fittings however opted to not. Some of the parents which are extra within the find out about energy steering techniques say that the 90 diploma fittings can cut back the movement and result in decrease efficiency.
Once the 5/8″ suction line was plumbed, I turned my consideration to the 2 remaining 3/8″ return strains. The current low stress return line from the Hydroboost was greater than lengthy sufficient to do the job. I lower about 6 inches off of it after which hooked up the -6 Twist-Lok becoming, utilizing the identical technique as I did on the suction line. When the Twist-Lok becoming was hooked up, it was screwed onto the -6 becoming that Troy had welded onto the facet of the reservoir. The remaining line that wanted one other -6 Twist-Lok becoming was the low stress return line from the steering field. Since I’ve a power steering cooler in my system, the return line truly comes out of the cooler and attaches to the inlet port on the reservoir. The low stress line from the cooler was not lengthy sufficient to achieve the reservoir. I had a hunch this was going to come back up brief and had already bought a 3 foot piece of low stress line. I used to be fortunate as that piece was simply lengthy sufficient to achieve. I had guessed on size and virtually got here up brief.
With the final of the return strains hooked up to the reservoir, I opened a quart of Valvoline SynPower energy steering fluid and began filling the reservoir. I added about two-thirds of the bottle.
With the reservoir crammed, it was time to bleed the ability steering system. First, I let it set UNDISTURBED for a couple of minutes whereas I rechecked my work (hose fittings, clamps, mounting bolts, and so forth.) Now is a superb time to find that you just uncared for to tightening that one becoming….higher now then after it’s below stress and spraying down your engine compartment with excessive stress energy steering fluid! I wiped down the pump physique, reservoir, and all of the fittings in order that any fluid leak may very well be simply detected.
Using a ground jack below the middle of the entrance axle, I raised it till one of many tires cleared the bottom. WITHOUT STARTING THE ENGINE, I slowly started turning the steering wheel lock to lock. The phrase SLOWLY is necessary….it means about 1 revolution of the wheel each 8~10 seconds. Continue so as to add fluid to the reservoir as needed. As I slowly labored the steering wheel forwards and backwards, the fluid stage rose and fell a bit because the bubbles labored their manner out of the strains. After a few dozen lock to lock turns, I checked the reservoir stage. I added 6 oz. of fluid to deliver it again as much as the identical level the place I initially crammed it. I did one other half dozen lock to lock cycles. The fluid stage barely modified in comparison with earlier than. Time to examine for leaks.
There have been no indicators of leaks on the brand new fittings I had put in. Satisfied that no apparent issues existed, I pulled the wire that connects the ignition cable to the distributor. (for you distributorless TJowners, you’ll have to skip this step). With the engine assured to not begin, I switched on the ignition key and let the engine crank for about 10 seconds. After cranking the engine, I did one other half dozen lock to lock cycles with the steering wheel. I then checked the extent within the reservoir. It had not modified. Looks good….time to start out the engine.
There was a NO noise from the ability steering system. I let the engine idle whereas I checked the reservoir fluid. Using a brilliant LED flashlight to light up the within of the reservoir, I made sure that there was no small bubbles or foam exhibiting up. Nothing….crystal clear the fluid was. Just what I hoped for.
With the engine at about 1200 RPM, I slowly cycled the steering wheel in each path, evenly contacting the wheel stops. All nonetheless sounded nice. If the pump begins to get noisy (whines or growls), flip the engine off and let the system set for about quarter-hour. Air within the system will trigger the pump to groan and the fluid stage will rise when the engine is turned off. Lots of tiny bubbles within the reservoir is an efficient signal of trapped air within the system. Repeat the above steps till your energy steering is working usually.
With the engine now turned off, I spent a couple of minutes placing a few of my instruments away. Another examine of the ability steering fluid indicated no change within the stage, which was good. Since the reservoir has no dipstick hooked up to the cap (just like the inventory reservoir does), I wiped a small screwdriver clear and used it. I wished to make sure I had sufficient fluid within the reservoir however not a lot that it could overflow when the fluid got here as much as working temp (or extra when the day was spent enjoying on the rocks and trails). I set the extent in mine to about an inch under the baffle plate. This makes for a number of inches of fluid excessive of the filter and the AN becoming that Troy welded. You don’t need the pump to ever suck air and also you don’t need it to overflow from growth both.
With the the system bled and the pump examined with the engine operating, I changed the windshield washer reservoir and the coolant reservoir. Everything match again into its unique place, no slicing, no dicing, no transferring issues round.
The 20 mile drive again to my place and the following startup the following morning yielded no surprises or pump noise. I popped the hood and did one other visible to ensure not one of the connections have been leaking fluid. All have been dry so I’ll take into account this venture successful!
Many because of Sean at Performance Off-Road Systems for what I count on to be an extended and blissful pump life. He promised me that I’d be very glad with the pump’s efficiency. I’ve acquired a path trip scheduled with a good friend in a few weeks and am trying ahead to seeing how the steering behaves within the rocks. As for the Hydroboost’s efficiency, it was working nice with the brand new pump throughout the journey residence from Troy’s store.
Good trails and keep in mind to TreadLIGHTLY!
