I was on my third factory power steering pump, which started leaking. So it was decided to stop being cheap and go with an aftermarket pump which would be far better suited for the eventual hydro assist that I will be running. EDIT: All pictures lost, sorry guys. I will include links to every part I ordered at the end.
I had two options:
1. AGR pump and reservoir
2. PSC High Flow Pump Kit
Both of them were roughly the same cost, but the PSC was sold in kit form including a belt and idler pulley. Also, having the smaller pulley on the pump would increase the performance of the steering down low in the RPM range, a nice stop gap between stock and hydro assist.
Here is a basic timeline/write-up of install, including discussions with PSC.
High Flow Pump
Serviceable hydraulic line for pressure and return
Instructions are for suckers, so I went about pulling the air box, factory power steering pump, and reservoir. With the kit laid down in front of me I located the reservoir bracket which I couldn't get to line up with anything. A quick search on PSC's site indicated the bracket I was shipped was for the TJ/YJ/XJ. I verified the kit was the proper kit and sure enough "07-11 JK" was printed on the box. I decided that was enough for the day.
Contacted PSC, sent them pictures of the bracket, and had a chat about instructions. They confirmed that it was the wrong bracket, told me that the universal bracket that was included was all I needed, and to use instructions for the ram assist install for location of reservoir. On 07-11 JKs PSC recommends mounting the reservoir on the battery box, directly above the passenger side manifold. This raised a few alarms, as they have updated their reservoir design. The new reservoir is far larger than the old reservoir (as far as I can tell from the pictures on the instructions) so large, in fact, that the hoses are within 6" of the manifold and the added weight caused the battery box to distort slightly. Far from a solid install IMO. I called PSC back and requested the bracket for a 12-18 mounting location, which they sent free of charge.
With the bracket in hand I mount the reservoir and test fit the air box. The reservoir fits, but the fittings don't clear. I ended up using a 3/4" JIC Male x #12 SAE/ORB Male 45°
for the pump supply and a 3/8" JIC Male x #8 SAE/ORB Male 90°
for the return line. I attached the push-locks that came with the kit to the JIC fittings which will enable me to remove the reservoir without cutting hose. If you decide to go this route, it takes some fidgeting with angles to get everything right. It will fit though, so be patient.
Hoses and system fittings came in. The JIC adapters I utilized for the pump and gearbox were purchased from Summit. These allow standard hydraulic JIC fittings to be attached. Pump pressure and gearbox return are -6 AN to 16mm x 1.5 Male
while the gearbox pressure is -6 AN to 18mm x 1.5 O-Ring
. For the high pressure line itself I utilized 3/8" SAE 100R2AT Hydraulic Hose
, for the pump fitting I used a 45° 3/8" Hose x 3/8" JIC Female
, and for the gearbox side I used a 90° 3/8" Hose x 3/8" JIC Female
. These are reusable fittings which was nice because I hooked the pump side fitting, routed the hose directly to the box and marked the exact length I needed. Very clean final install. Use an angle grinder to cut this hose, I attempted a hacksaw, and I would still be there if I kept that plan.
With the pressure side hooked up, I shifted my attention to the return side. First things first, I needed to mount the cooler, which was a Derale 13263 Dual-Pass Heat Sink Cooler Kit, 12
. Looking back, I should have just bought the bare cooler, since I ended up buying new lines and fittings anyway. One thing I didn't notice with the cooler when I bought it, was that it is a dual pass, which means the inlet and outlet are on the same side so the standard in on the driver side, out on the passenger side wont work here. I just oriented it so inlet/outlet were on passenger side. To physically mount it, I welded some tabs to the cross-member in front of the radiator, drilled, tapped to 1/4"-20 and used grade 8 hardware for mounting. Return hose from gearbox to cooler was 3/8" Black PUSH-LOCK Hose
,gearbox return fitting was a 3/8" PUSH-LOCK x 3/8" JIC Female Swivel 90°
cooler fittings were both 3/8" PUSH-LOCK x 1/4" NPTF Male Pipe
. These fittings do not need hose clamps, they aren't standard barbed fittings. A little dab of power steering fluid on the fitting prior to installing the hose will go a long way.
After completing install, I blew a little air through the gearbox to help get rid of any residual ATF +4 and used the recommended SWEPCO 715 power steering fluid to bleed the system. There is still some ATF+4 in the system. I'm going to run it, its very diluted.
At idle it turned aired down 35" Toyos on textured concrete without a problem. The engine actually loads up when the steering gets heavy.
The hardest part of this project was the parts research. I did my best to include hyperlinks to everything I purchased. When I get home tonight I will make another attempt at pictures.
Parts and links:
Kit: 2007-2011 Jeep JK 3.8 XD Steering Pump Kit
Reservoir to pump supply fitting: 3/4" JIC Male x #12 SAE/ORB Male 45°
Return to reservoir fitting: 3/8" JIC Male x #8 SAE/ORB Male 90°
Gearbox Pressure JIC adapter: -6 AN to 18mm x 1.5 O-Ring
Pump pressure and gearbox return JIC adapter: -6 AN to 16mm x 1.5 Male
Pressure hose: 3/8" SAE 100R2AT Hydraulic Hose
Gearbox pressure fitting: 90° 3/8" Hose x 3/8" JIC Female
Pump pressure fitting: 45° 3/8" Hose x 3/8" JIC Female
Cooler: Derale 13263 Dual-Pass Heat Sink Cooler Kit, 12
Return hose: 3/8" Black PUSH-LOCK Hose
Gearbox return fitting: 3/8" PUSH-LOCK x 3/8" JIC Female Swivel 90°
Cooler Fittings: 3/8" PUSH-LOCK x 1/4" NPTF Male Pipe