Sag swap, york install, power steering cooler, Ghetto K&N install

[California Monkey]

This is how it starts







Tear down







The junkyard parts I went with

A sag power steering pump out of a 89 econoline van with high pressure line (make sure to find a capwhen you grab this)



A York out of a 70's ford pick-up. It's the 210 model which originaly had a V-belt pulley on it.



(this is how the shaft on the 210 york looks like)



Here's the three main parts I was planning on installing. I went with a different cooler in the end when I saw how much easier it would be to mount it.





I had to remove the light and it's mounting tab to make room.



Then I mounted up the cooler making custom mounting tabs.



I then got a serp belt pulley for the york from Ryder for $95 shipped. It's sweet.



I then did the "oil mod" which is easy and keeps up to %90 less oil from escaping the york. You just put a screw in the little hole leading down to the back of the pulley.





I then mounted the sag (direct bolt up) and started making the mounting plate for the york. The first peice is 1/4" thick 6"X4-1/2" plate with the bolts being 10MX1.50 pitch and about an 1" long.





The second plate is a 1/2" plate 6"X7-1/2" peice with the bolts being a 3/8-16X3/4".





Leave room to get to the cap for the power steering



The elignment is very important. Front and back and in line with the other pullies.



A little extra bracing out of some scrap 1/4" plate



All the welds were done with flux core using the "anti-spatter" spray. This pic is with only a light wipe down. No real clean-up.



Paint it up black of course



And mount it all up once and for all with blue locktight



I then modified the power steering lines to allow me to have the cooler plumbed in and finished the job using tranny line and hose clamps



Finding a belt for the new serp set-up proved to be a challenge. Here's two helpfull tips.

1. Napa has the biggest variety of sizes

2. buy multiples and return which ones arn't right. It'll save you trips

The York doesn't allow me to use the stock air inlet lines to the throttle body so some modifacations had to be made





The stock air box is cool and all but the wife hooked me up with the K&N so I had to make some stuff for that as well



And making room for it, this mounting tab for the fuse box had to go. My fuses have been broken off and laying there for a while now so it was quick and painless





and I made the mounting bracket for the filter. This one I made out of some thin scrap but later re-made it out of 1/8" plate to make it stronger



The filler peice for the air intake came by way of some flexable exhaust tubing (2-1/8"). It worked really well



The on board air was already in place before hand using the stock A/C pump. It was ok but no york. The "manifold" had to be re-done. I made it up and made the bracket with the air intake off. Big mistake





That air switch had a built in unloader which I thought I needed. It ended up not fitting with the intake hoses in place so I used a smaller one I got off Ebay for $20 shipped.



I then worked the stock fittings from the york to accept my inlet filter



And my outlet going to the filter. I worked up a copper compression fitting for the unloader that I now won't be using. It really doesn't need it



Then just plumbed a line back to my original manifold going to the tank / rear line and to the front of the truck



Final conclusion.... The York is rediculous and insanely powerfull. The Sag makes me mad I didn't do it sooner and the K&N is much cooler looking than the stock air box in my opinion. I even replaced a bad coolant temp sensor while I was in there as well cleaned up a bit. I'm extremely happy with the outcome. I ended up going snow wheeling this weekend and at the end of the day, I ended up filling 17 tires before leaving. The york is absolutley impressive.
Thanks
Rich

Rich

[California Monkey]

turns out that the ghetto K&N isn't CA smog legal. I had to swap back for smog. Anyone know someone selling CARB legal stickers?

[jopes]

Originally Posted by California Monkey

turns out that the ghetto K&N isn't CA smog legal. I had to swap back for smog. Anyone know someone selling CARB legal stickers?

no, but when I start buying parts after I move I will be sure to keep them to sell to you clowns.

[California Monkey]

Iv'e since had multiple problems with the exhaust port hose off the compressor where the heat and oils "popped" the hose off or apart. So I fixed it good.



sim sim salabim!



The new hose has swivel fitting at both ends making it way easier to install and un-install as well as being able to withstand engine heat, compressor heat, gas and oil spills as well as being a 1000 PSI hose and crimpings.

The downside to never having to worry about this hose again was the price. $32

You figure by the time I put 4 + hose clamps, 3 plus fittings and hose on the old one, I was probably $15 into it. Cheaper to do it right the first time. The upside is I have the old hose I can part out for fittings and clamps.

[Joe'Bronco]

K&N is smog legal in CA, mine passed just fine.

Take the trip to Antioch (30min drive) and go to Firehouse smog next time you need to, they passed me with a bassani "offroad only" cat. All they care about is if your truck runs clean.

[M.L.S.C.]

Joe'Bronco, methinks that's not something you should be openly saying on a public internet board - it's super nice them people there pay attention to what's really important (truck running clean) and disregard the pencil-pusher-inspired details, but this is against Commiefornia's law and can get them in big trouble...

[giftskate4life]

32$ still isnt that bad considering how much better that hose looks and will preform, where did u buy that, if ya dont mind me asking?
Idk if this is a noob question but whatever, The two wires on top of the brass fittings after the filter, were are these run to?

[EastLA78Bronco]

on my oba i had the same problam..the heat and oil keeped popoing off the house..so i bought the exact same house as u for 10$...works and looks great

[California Monkey]

Thanks for the tip on the smog shop.

The hose I got was from Tubes and hoses in Livermore, CA

The two wires are connected to an air pressure switch so the pumps electric clutch only activates when the air pressue is below 90 PSI and runs until it hits 120 or something like that.

The hose worked great this weekend. Went snow wheeling so everyone aired down and I ended up filling 10 tires. No problems!

[RevSJamison]

Originally Posted by Joe'Bronco

K&N is smog legal in CA, mine passed just fine.

Take the trip to Antioch (30min drive) and go to Firehouse smog next time you need to, they passed me with a bassani "offroad only" cat. All they care about is if your truck runs clean.

How far is Antioch from Sac? Timewise. I still haven't registered my Bronc in CA yet....still has WA plates.

[Joe'Bronco]

Originally Posted by RevSJamison

How far is Antioch from Sac? Timewise. I still haven't registered my Bronc in CA yet....still has WA plates.

Than they may be a little more strict on ya since its your first time regestering in CA. And remember they are loose on the visual, not blind. You still have to pass the sniffer tests. You may have to go to a Smog location in the Sac area.

FYI - Sac to Antioch is about an hour and a half.

[badass1tonf100]

Out of curiousity.... What application is the tranny cooler you actually bolted up from?

[giftskate4life]

For that power steering pump, what other years will bolt directly up? and is it only e series vans that have this better pump? im sure this has been covered but i couldnt find it searching

[California Monkey]

Originally Posted by badass1tonf100

Out of curiousity.... What application is the tranny cooler you actually bolted up from?

This came out of a late 70's / early 80's volvo which have Yorks in them as well.

Originally Posted by giftskate4life

For that power steering pump, what other years will bolt directly up? and is it only e series vans that have this better pump? im sure this has been covered but i couldnt find it searching

It's covered in the tech section under sag swaps. I thkn this particular one would go under 87 - 94 non I6 engines. If you have an I6 or other years, I think the sag info threads cover where to find those as well. It's completely worth the swap. No more whine and the tires turn with little effort even under strain. don't wait any longer.

[SomeDude451]

If you want, I may have still have the CARB sticker from my K&N sitting around my house. As soon as I get back from the TDY I'm on, I can have a look if you'd like.

[California Monkey]

That'd be sweet. I'd gladly pay for your troubles.

[SomeDude451]

For a sticker, an envelope and a stamp? That's really not necessary, but thank you. I should be home Friday next week. I'll have a look and let you know.

[Joe'Bronco]

The sag pump is my next upgrade. Went to the pick&pull in Hayward and they closed down ($24 for the pump & bracket). The next closest place wanted $75 for the bracket and a busted pump

Whats a good price for the Sag Pump & Bracket?

CalMonkey - Where did you get yours?

[justin]

I paid about $27-28 at the P&P for the bracket, sag pump, HP hose, pulley, and bolts.

[California Monkey]

I got my Sag from a pic and pull in stockton and I got the sag from a pick and pull from fremont (mowry ave). I want to say the sag with bracket and hoses was around $55 -$60 and the york was $20 or $25. Pickyourpart closed for good which was the only place keeping the pick and pulls prices down.

Try some of the non "chain" pick and pulls like they have in Brentwood and whatnot.