Tapping Steering Gear Box for Hydraulic Assist Lines (PICS) + ram/hose install

[Bronkzilla]

Figured id take some pics since i havent found a nice clear set of them online.

Id recommend that you rebuild your gearbox while you have it off and empty.
Here is the writeup i used http://4x4.forensick.net/88bronco/images/sbr/index.htm
its very detailed and made it very easy to rebuild mine.

Onto the tapping.. I will assume that you will be rebuilding it as well.. Click on that link above and do steps one through ten. (if you are just tapping it then do not remove any bearings)

Heres what the box looks like empty and clean.





For the first fitting mark a point 1/4 inch in from the top right corner (i removed the paint from this raised area so you could see it better)


I started off with a small bit and kept increasing the size until i got to the size i needed. Since my fittings used a 1/4 npt thread i stopped at 7/16".




use your tap and tap it. I was told not to tap it all the way through so that the fitting seals better. i threaded 3/4 of the hole.


bad picture but you can sort of see the threads.. damn flash..



the next hole is a bit tricky.. You need to keep the fitting centered so that it forms a T with the hole inside. Be careful not to go through the hole and into the main body. Drill in enough just to create a T.. For my box i used 1" in from the left and 1/2" up from the bottom. You can see the mark in this pic.


once again.. start small and keep going till you reach the right bit.. better safe than sorry..






here you can see what i mean about not going through into the main body.. the fluid actually moves into that shaft that you just T'd into through that slot on the bottom right in this pic..


install the fittings.


go back to the rebuild writeup and go onto step 11..


thanks to reptillikus for his awesome rebuild writeup and to zack for the fuzzy pic of his tapped box..

[Bronkzilla]

found this on pirate.. shows you how the steering gearbox works..
pretty cool....

[axaviere]

dude, thanks for making it easier for the rest of us.

[gearrat]

looks good rafa when ya going to have it back on the bronco?

[reptillikus]

Wow, so thats all thats involved with tapping the box? Awesome!
Oh, and what kind of fittings are those?

[Bronkzilla]

Originally Posted by reptillikus

Oh, and what kind of fittings are those?

the fittings are supposed to be JIC to NPT but after doing some reading online i found out that JIC and AN fittings are almost exactly identical.. Enough to not even matter.. I was able to find the AN to NPT fittings and thats what i used. 1/4 NPT is what went into the box. The other end connects to the JIC fittings on the hydraulic hose.


bought them here http://www.pitstopusa.com/EARNPT-ANADAPTERS.asp

here is a link to the original thread.. http://www.fullsizebronco.com/forum/...ead.php?t=8888

[BigNorm]

You Rock Raf! Thanx a bunch!

[Aikidoka]

Neat. Is there a thread out there that shows the rest of the system set up? I found this http://fullsizebronco.com/forum/show...draulic+assist but wasn't sure if it was a different type of install.

[Bronkzilla]

ill post pics of the rest of the setup as soon as its done.. right now im trying to figure out how to mount it..

[BigNorm]

What kind of ram is that Raf? I was thinking of trying to use one off of a combine like Baddassbronco did.

[Bronkzilla]

that is an agr rock ram.. got it on pirate4x4.com real cheap..

[Aikidoka]

What type of pump is in there now?

[Bronkzilla]

the ps pump is a saginaw pump..

[TRUCKY18]

Ok, just trying to figure out what the point is, in the end will you not have the pitman arm any more or what? Sorry just trying to figure out whats goin on

[axaviere]

you keep all your stock steering rods and components. you just attach the ram to the tie rod on one end and the axle housing on the other. its hydro assist-ing your stock steering system

[Bronkzilla]

Originally Posted by TRUCKY18

Ok, just trying to figure out what the point is, in the end will you not have the pitman arm any more or what? Sorry just trying to figure out whats goin on

like axe said. all your steering stays the same. you just add this ram to help it move the tires..
im trying to move these things..

[locopny]

Raffa-
you see my reply at wt?

[Bronkzilla]

Originally Posted by locopny

Raffa-
you see my reply at wt?

yup.. just replied..

[TRUCKY18]

gotcha, thanks

[Bronkzilla]

Mounting the ram.. The ram should be attached to the axle and the tie rod.. I didnt have the room to mount it from the axle tube to the tie rod so i mounted it from the tie rod to the diff cover.. I did alot of searching and reading on 4x sites and the web and found many attached to the diff cover. Im going to try it and keep an eye on it. If there are any problems ill modify it..

(the drag link is sitting above the pitman arm to represent its final location when i get a new smaller pitman arm)

some pics..
(going straight)


(right turn)


(left turn)


Next i had to make the hoses... I cycled the suspension and took measurements in order to cut the hoses to length..


Cut the hose with a thin cut off wheel.


2 piece fittings so you can make your lines at home..


first install the outer piece over the hose.. turn it counter clockwise to thread it on.


splash some wd40 or ps fluid on the hose then install other part of the fitting.. it threads in normally..


completed..



this is a ps resevoir neck extension.. your supposed to use the shrink tube to connect the extension to the existing neck..


damn blowdryer wasnt hot enough.. ill have to find a heat gun..


Connect the hoses and bleed the system.. Ill see if i can find the bleeding instructions in the garage.. if i do ill add them to this page..